Plastimo S Series User manual

PLASTIMO JIB REEFING SYSTEMS
S-SERIES
406-S 608-S 810-S
GB

2
ASSEMBLY INSTRUCTIONS FOR S-SERIESASSEMBLY INSTRUCTIONS FOR S-SERIES
406-S 608-S 810-S406-S 608-S 810-S
I N D E X
Technical specifications of 406-S, 608-S, 810-S 3
Description of specific parts for each model 6
Tools needed 8
FLAT ASSEMBLY (forestay dismantled)
Dismantling the forestay 9
Assembly of the jib reefing system 10
IN SITU ASSEMBLY (directly onto the boat)
Measuring the length of the forestay 13
Cutting the lastspar 14
Assembling the top end stop 15
Assembling the spars 15
Assembling the base spar 17
Assembling the boltrope prefeeder 18
Assembling the drum unit 18
Adjusting the reefing line feeders 19
RECOMMENDATIONS
Recommendations 20
Maintenance 21
Troubleshooting 21
OPTIONS
Optional extras 22
Spare parts 23

3
TECHNICAL SPECIFICATIONS
406-S MODEL
45
50
119.5
A
B
D
117.5
Ø 132
Ø E
C
S
Ø 6,5 mm
Ø 4 - 7 mm
450
Model 406-S
Réf. N° chainplate version 25722
Réf. N° turnbuckle version 25723
Forestay diameter (mm) 4 - 7
Luffrope diameter (mm) 6.5
Length Achainplate (m)
Length A turnbuckle (m) 6.20 6.28
Length B (m) 5.95
Length C chainplate (mm)
Length C turnbuckle (mm) 85 170
Lenth.D (m) 5.82
S (m²) 12
ØE (mm) 8.5
Bearings Delrin ®
Coupling units aluminium
+ screws
Number of grooves 1

4
608-S MODEL
45
50
128
A
B
D
S
129
C
Ø 184
Ø E
Ø 6.5 mm
Ø 4 - 7 mm
450
Modèle 608-S
Réf. N° chainplate version 25724
Réf. N° turnbuckle version 25725
Forestay diameter (mm) 4 - 7
Luffrope diameter (mm) 6.5
Length Achainplate (m)
Length A turnbuckle (m) 9.22 9.40
Length B (m) 8.94
Length C chainplate (mm)
Length C turnbuckle (mm) 115 285
Lenth.D (m) 8.80
S (m²) 25
Ø E (mm) 12.5
Bearings Delrin ®
& stainless
steel
Coupling units aluminium +
screws
Number of grooves 1

5
810-S MODEL
45
50
128
B
A
D
352
Ø190
ØE
C
Ø 6.5 mm
Ø 4 - 7 mm
S
650
Modèle 810-S
Réf. N° chainplate version
Réf. N° turnbuckle version
25374
Forestay diameter (mm) 4 - 7
Luffrope diameter (mm) 6.5
Length A (m) 11.05
Length B (m) 10.44
Length C (mm) 220
Length D (m) 10.49
S (m²) 35
Ø E (mm) 14.3
Bearings Delrin ®
& Torlon ®
Coupling units aluminium
+ screws
Number of grooves 1

6
DESCRIPTION OF SPECIFIC PARTS FOR EACH MODEL
406-S model
- 1 drum unit
- 1 halyard swivel
- 2 TCL screws M4 x 12 ( to secure reefing line feeder 406-S)
608-S model
- 1 drum unit
- 1 halyard swivel
Enrouleur 810-S
- 1 drum unit
- 1 halyard swivel

7
Standard parts for all models
- 1 boltrope prefeeder
- 1 top end stop
- 2 bearings
- Coupling sleeves
- 406-S ðQty 4
- 608-S ðQty 6
- 810-S ðQty 7
- 1 base spar
- Intermediate spars
- 406-S ð3 spars
- 608-S ð5 spars
- 810-S ð6 spars

8
- PVC liners
- 406-S ð4 liners
- 608-S ð6 liners
- 810-S ð7 liners
-Screws
- TF M5 x 8 screws for spar connections
- 406-S ð6 screws + 2
- 608-S ð10 screws + 2
- 810-S ð12 screws + 2
- 4 N°7 TFscrews (3.9 x 9.5 ) tosecure prefeeder.
- 1 N°10 TF screw (4.8 x 12.7 )
- 1 Chc M5 x 12 screw to secure base spar to drum
TOOLS NEEDED
- Hammer
- Pliers
- Comfortable bosun's chair (Plastimo).
- Allen key (∅4)
- Electric or hand drill
- 1 ∅4 mm drill
- Hacksaw
- Tape measure
- Screwdriver
- Silicone filler.

9
FLAT ASSEMBLY
- This method consists of fully dismantling the forestay and assembling the jib reefing system while the forestay is lying flat.
- We recommend this method as it is faster.
- In certain cases the top part of the forestay cannot be dismantled, in this case::
ýdo an in situassembly (see page 15)
ýcontact a professional who can install a universal joint on the upper part of the forestay.
Steps to be followed:
DISMANTLING THE FORESTAY
Lower part
- Slacken the backstay
- Secure the mast forward with 1 or 2 halyards
- Tigthen the halyards to relieve the strain on the forestay
- Dismantle the lower part of the forestay (this usually consists of removing a removing a rigging screw pin, or a
screw and a nut)).
Note : it is important to measure the distance between the forestay eye and the hole of the forward mounting plate in order to
find the correctadjustments again.
For a turnbuckle assembly, measure the distance between the mounting plate and the blocking nut of the turnbuckle.
halyard to secure the mast
forestay
slackened backstay
Upper part
- Send a person to the masthead (equipped with hammer and pliers)
- Dismount the upper part of the forestay
- Bring the person and the forestay down from the masthead
drisse pour assurer le mât
étai pataras détendu

10
ASSEMBLING THE JIB REEFING SYSTEM
- Lay the forestay flat
- Place the parts tobe assembled alongside the forestay
- Assemble the drum unit on the forestay and put the rigging screw pin or screw and nut in place (select the chainplate hole that
corresponds to the initialforestay adjustment)
- Slide a bearing into the drum
- Insert a coupling sleeve into the basespar (ensure that the hole in the coupling sleeve is in line with the pre-drilled hole of the
basespar)
- Slide the basespar into the drum unit until the two holes are in line, insert the Chc M5 x 12 screw (after putting some silicone
filler in the hole in order to reduce the stainlesssteel / aluminium electrolytic couple) and tighten.
- Install the boltrope prefeeder; ensure it is the rightway up, see diagram below.

11
- Secure with the 4 N°7 (3.9 x 9.5) TF screws
- Insert an aluminium coupling sleeve, put some silicone fillerinto the hole and position a TF MS x 8 screw (do nottighten or
it will be difficult to put the secondscrew in place).
- Put a secondspar into position, putsome silicone filler in the hole and position thescrew (once the two screws are in position
they may both be tightened). Wipe off any excess filler with a cloth.
- Insert PVC liners asyou go along (ensure they are flush against the prefeeder)
- Repeat the process until only one spar is left
Cutting the last spar
- Position the lastspar so that it lies flush against the previousspar but do not install it
- Measure a distance of 5 cm back from the sleeve of the forestay
- Mark and cut the spar with a hacksaw
- Put a coupling sleeve into position
- Insert the spar, then insert and tighten thescrew
5 cm
- Position the last PVC liner
- Mark the liner level with the end of the aluminium spar
- Cut and insert the PVC liner
mark
end of last PVC liner

12
Installing the top end stop
- Slot the secondbearing into the top end stop
- Slide the top end stopover the aluminium spar
- Drill ahole (with a 4 mm drill)
IMPORTANT: refer to diagram for the positioning of the top end stop
- Before putting the screw into position, do notforget to slide the halyard swivel into place (ensure that the conical end of the
halyard swivel faces downwards)
- Put the top end stop back into position
- Put some silicone filler into the hole
- Insert and tighten N°10 TF screw (4.8 x 12.7)
- Your jib reefing system is now assembled and can be put into position (hoist it up to the masthead with a halyard)

13
IN SITU ASSEMBLY
ýthis method of assembly may be carried out by one person
ýit is not necessary to dismantle anything at the masthead
Steps to be followed:
MEASURING THE LENGTH OF THE FORESTAY
- In order for this jib reefing system tobe perfectly adapted to your boat the length « X»needs to be known.
Helpful hint:
- Slide a small shackle around the forestay
- Ensure that it lies flushagainst thesleeve
- Slacken the backstay
- Secure the mast with a halyard
- Dismount the lower part of the forestay
- Assemble the drum unit
- Reassemble the lower part of the forestay
- Undo the halyard and tighten the backstay
X

14
- Attach a halyard to the shackle
- Attach a length of rope (or a tape measure) to the shackle
- Hoist the shackle until it touches the topsleeve of the forestay
- Mark the piece of rope level with the top of the drum unit
- Lower the shackle
X
CUTTING THE LAST SPAR
Stretch out flat the piece of rope used to measure the length of the forestay
- Lay the aluminium spars parallel to the piece of rope (take note of base spar, see page 7)
- Mark the spar level with the mark on the piece of rope
- Cut the spar 3 cm (safety margin) below the mark
3 cm
location of mark on the piece of rope

15
ASSEMBLING THE TOP END STOP
- The top end stopshould be assembled on the aluminium spar that has just been cut.
a) The second bearing is slotted into the top end stop
b) Slide the top end stopfully over the end of the spar
(IMPORTANT: refer to diagram below for positioning of the hole in the top end stop)
c) Drill a hole using a ∅4 mm drill
ASSEMBLING THE SPARS
- Dismount theforestayfrom the stemheadfitting
- Install the following on the forestay:
Top end stop
Bearing
The sparthat you have cutand drilled
N°10 screw
PVC liner
N°10 screw
Halyard swivel (IMPORTANT: see drawing below for position of halyard swivel)

16
- Refasten the forestay
- Attach a halyard to the halyard swivel in order to support thespars as they are assembled
- Insert a coupling sleeve
- Put some silicone filler into
the holes before tightening
the screws (in order to reduce
the electrolytic couple
between the stainlesssteel
screw and the aluminium)
- Insert an M5 x 8 screw
- Wipe away any excess
silicone with a cloth
- Slide another aluminium spar
into position
- Insert a PVC liner
IMPORTANT: keep the base
spar to oneside; you will be
assembling it last)
- Repeat the process as many
times as necessary

17
ASSEMBLING THE BASE SPAR
- IMPORTANT: ensure the base spar is facing the rightway (see diagram below)
holes to secure
prefeeder
end to be inserted
into drum
-Cutting the PVC liner
- Slide the prefeeder into position
from the bottom of the spar until it is
in line with the holes in the spar
(IMPORTANT: ensure that the
prefeeder is the rightway up)
- Insert a N°7screw
- Position a PVC liner, mark and cut
to required length
- Remove the prefeeder and install the
cut PVC liner
position ofprefeeder

18
INSTALLING THE BOLTROPE PREFEEDER
- Put the prefeeder back
into position
- Put some silicone filler
in the holes
- Insert and tighten the 4
N°7 screws
- Wipe away any excess
filler with a cloth
ASSEMBLING THE DRUM UNIT
- Detach the forestay from its
mounting plate on the boat
- Position the sleeve or
turnbuckle* on the drum
(*depending on model)
- Slide a bearing into the
drum
- Insert a coupling sleeve into
the base spar (ensure that
the hole in the coupling
sleeve is in line with the
pre-drilled hole of the base
spar)
- Insert the basespar into the
drum unit
- Put some silicone filler in
the pre-drilled hole
- Insert the Chc M5 x 12
screw
- Attach the jib reefing
system to the forward
mounting plate
- Lower the halyard swivel
- Tighten the backstay

19
ADJUSTING THE REEFING LINE FEEDERS
406-S model
- The reefing line feeder on the 406-S model is assembled either on the right or left hand side of the drum unit, depending on
which direction you prefer to reef.
- To fasten the reefing line feeder, use the two M4 x 12 nuts and bolts (see page 6)
starboard assembly port assembly
- The angle is adjusted by loosening the two screws that hold the chainplate.
screws
608-S & 810-S models
- The angle ofreefing line feeders on 608-S & 810-S models is adjusted by loosening the two nuts and bolts (see diagram
below)
nut and bolts

20
RECOMMENDATIONS
Reefing line feeders
ýThe angle of all the reefing line feeders may be adjusted.
IMPORTANT: they should be positioned in a way that best suits the direction of pull on the line
Reefing line
ýThe reefing line is wound around the drum.
Only use pre-stretched rope in order to eliminate any elasticity
Refer to diagram below for the position of the reefing line asit comes out of the drum
90°
1 m
Reefing direction of the genoa
ýThe genoa should be reefed in the same direction as the strands turn on the forestay.
When you are notsailing
ýSlacken the backstay in order to reduce unduestrain on mechanical parts
About the drum
ýWhen your genoa is fully reefed and in order to avoid direct strain on mechanical parts and on the knot of the reefing line,
there should be a minimum length of one halyard turn on the drum.
Halyard/forestay angle
ýThis angle should never be more than 20-25° asthis makes it impossible to tauten and reef the sail.
What is more, this unduestrain on the forestay could cause it to unravel and even dismast the boat...
25° maxi
Whensailing
ýEnsure that the forestay is always taut. Not only will this make reefing easier but will avoid any danger of the forestay
unravelling. (We recommend putting a universal joint at the masthead)
Hauling on the genoa
ýThe reefing line should never be used to haul on the sail.
Unfurling the genoa
ýWhen unfurling the genoa, ensure that it does not unfurl too quickly by winding the reefing line once round a winchand
feeding it out slowly in one hand and the genoa sheet in the other.