Selden Furlex 50 S User manual

Manual
Furlex 50 S
595-982-E
2015-04-17
50 S

2
This information must be followed to avoid damage to the system and the risk of
personal injury.
The 2 year guarantee on the Furlex-system is only valid if the system is assembled and
operated correctly according to the manual.
1 Introduction
PLEASE read the entire manual prior to assembly.
Seldén Mast AB guarantees the Furlex-system for 2 years. The guarantee covers faults arising from
defective design, materials or workmanship.
The guarantee applies only if the Furlex system has been installed, operated and maintained in accor-
dance with this manual and has not been exposed to greater loads than those given in the brochure and
instruction material.
Complete shipment and warranty conditions are to be found on Seldéns website www.seldenmast.com.
See Resources/Partners information/General information/General conditions of sale (595-546-E).
If the system is repaired by anyone other than Seldén Mast AB or one of our authorised dealers, the
guarantee ceases to be valid.
1.1 Instructions
In order for you to gain the most benefit and enjoyment from your Furlex system, we recommend
that you study these instructions thoroughly.
The manual is divided into a section for ASSEMBLY and a section for OPERATION.
Both sections contain references to the other. It is very important that these instructions are read
and observed.
All safety-related information is indicated by the following symbol:
The manual applies to Furlex type 50 S.
The model designation can be found on the top of the line drum.
All dimensions specified in the manual are in millimetres (mm) unless otherwise indicated.

3
Page
1 Introduction
1.1 Instructions 2
1.2 Product information 4
ASSEMBLY
2 Check list
2.1 Furlex box 6
2.2 Foil pack 8
2.3 Tools 8
3 Assembly preparations
3.1 Forestay attachment – main principle 9
3.2 Mast attachment 9
3.3 Deck attachment 9
3.3.1 Measurement table for lower
bearing assembly 10
3.3.2 Measurement table for upper wire terminal 10
3.3.3 Measurement table for toggles 11
3.4 Assembly below deck 12
3.5 Calculation of forestay wire length 13
3.5.1 Calculation table 1:
Forestay wire length 13
3.6 Calculating the length of the luff extrusion 14
3.6.1 Calculation table 2:
Length of luff extrusion 14
4 Assembly of the Furlex-system
4.1 Assembly of the luff extrusion 16
4.2 Wire assembly 17
4.3 Fitting the line and sail feeder 19
4.4 Fitting the line guard and line guide 20
fitting
5 Halyard routing
5.1 Halyard routing 21
5.2 Halyard sheave box 22
5.2.1 Sheave boxes 22
5.3 Spinnaker halyard 22
5.4 Fitting the halyard leads 23
6 Arrangement for the furling line
6.1 Functional description 24
6.2 Loading the line drum 24
6.3 Furling line routing 25
6.4 Assembly of stanchion blocks 26
7 The sail
7.1 Adapting the sail to the Furlex system 27
7.1.1 Measurement table for sail 28
Page
7.2 Shape of the sail 28
7.3 Determining the length of the pendant 29
OPERATING INSTRUCTIONS 30
10 Halyard routing 31
10.1 Summary 31
10.2 Halyard sheave box 32
10.3 Spinnaker halyard 32
11 Sailing with Furlex
11.1 Hoisting the sail 33
11.2 Unfurling the sail 34
11.3 Furling the sail 35
12 Reefing
12.1 Luff extrusion 36
12.2 Reefing under sail 36
12.3 Reefing with furled sail 36
12.4 Adjustment of sheeting point 36
14 Adjustment of forestay length 37
15 Maintenance of the Furlex system
15.1 Lubrication of lower bearing assembly 38
15.2 When Furlex is off the boat 39
15.3 Storage 39
16 Rigging
16.1 Rigging on a stepped mast 40
16.2 Stepping mast with Furlex fitted 41
17 Dismantling
17.1 Halyard swivel 42
17.2 Sail feeder 42
17.3 Line guide 43
17.4 Forestay 44
17.5 Lower bearing assembly 45
17.6 Luff extrusion system 45
18 Trouble Shooting 46
19 Check list
19.1 Check points before sailing 48
Contents

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When Furlex was introduced in 1983, it quickly became the market leader, a position it still occupies
today. The first systems sold are still functioning well. Providing ample proof of the design’s
effectiveness and long-term staying power. Our success can also be put down to how we select a
system for a specific yacht. First we calculate the boat’s righting moment, which is the function of its
displacement, ballast, beam and draught. Then we use righting moment in combination with the rig
type to calculate its power when sailing, and the likely loads on the Furlex system. In this way, we
achieve a correctly dimension jib furling system for each individual yacht.
It has always been our intention to retain responsibility for our products through all stages of supply.
Furlex is therefore only sold through local, authorised dealers who can satisfy all of our customers
requirements. This includes assistance with assembly, the modification of sails or the production of
new sails, as well as service.
Furlex is supplied as a complete assembly kit containing all the components required.
The halyard swivel ball bearing system features a load distribution facility. A unique patented
system which distributes loads over the entire ball race. This permits smoother furling and consid-
erably reduces wear on the bearings.
The Furlex-systems luff extrusion has the same size along its whole length. The entire luff is rolled
up in an even roll, all the way down to the tack attachment. This allows for a good shape to a
reefed sail.
Furlex is manufactured by Seldén Mast, the world’s leading manufacturer of masts and rigging
systems. We wish you fine sailing with your Furlex.
1.2 Product information
Follow the instructions carefully when assembling the system.

5
1. Forestay/Eye terminal
2. Top guard
3. Halyard swivel
4. Sail head shackle/Tack shackle
5. Luff extrusion
6. Distance tube
7. Join sleeve
8. Sail feeder
9. Sail feeder connector
10. Lower bearing assembly
11. Toggle (Fork/fork)
12. Line guard housing
13. Line guard bracket
14. Line guide fitting
15. Wire terminal marked with
forestay size
16. Lock block
1
11
12
13
14
15
2
3
4
4
5
6
7
8
9
10
16

6
Forestay wire
Halyard swivel with head shackle
Lower bearing assembly with tack shackle
Line guard unit
Line guide fitting
Lock block
2 Check list
2.1 Furlex box:
ASSEMBLY

7
Furling line
1 guide leads 508-135, incl. 2 screws and
insulating washer
Drill bit Ø 5.3 mm
1 stanchion block
Prefeeder with rope
Locking adhesive
Grease
Top guard incl. 1 screw
Manual
Spare parts list
Certificate of guarantee

8
1 x 600 mm extrusion with join sleeve and
distance tube
1 x 2000 mm extrusion with distance tube
2–4 x 2400 mm extrusions with distance tube
+ join sleeve
Sail feeder (Sail feeder + sailfeeder connector)
1 long connecting plate for the 600 mm
extrusion.
1 short connecting plate for each 2400 mm
extrusion.
2.2 Foil pack
Tools needed for assembly:
Flat blade screwdriver
Hacksaw
2 adjustable spanners
Polygrip pliers
Adhesive tape
File
Marker pen (water-proof)
Torx keys T15, T20, T25, T30
Steel measuring tape (20 m) (100”)
Knife
For the halyard lead:
Heavy-duty TORX T30 screwdriver
Drill
Drill bit Ø 5.3 mm (included in Furlex
package)
2.3 Tools

9
Forestay attachment on top fitting with
masthead rig: Always connect via a toggle, to
give sufficient transverse flexibility.
Forestay attachment on a fractional rig of type
Seldén triple combi: 505-011; Ø 4 & Ø 5 mm
wire: Connected directly to the fitting.
Forestay attachment type Seldén 0-22 (517-
904). Connection directly to the fitting provides
sufficient flexibility
Forestay attachment type “T-terminal”
Intermediate connection with T/fork toggle. (See
table 3.3.3.)
Fig. 3.2.a Fig. 3.2.b
Fig. 3.2.c Fig. 3.2.d
FL
FL
FL
H FL
3 Assembly preparations
3.1 Forestay attachment – Main rule
3.2 Mast attachment - Main principle
Some of Seldén’s forestay attachments are shown below, they illustrate rules and exceptions. For
information concerning H-measurement, see table 3.3.3.
The guiding principle is that the forestay connections should allow sufficient articulation
in all directions. In most cases a toggle should be fitted between the Furlex stay and
the forestay attachment.
3.3 Deck attachment
The lower end of the Furlex system is fitted as standard with a fork toggle. This can normally be
connected directly to the boat’s forestay fitting.
Check that the lower bearing assembly and line guide do not collide with the pulpit, lights or other
deck fittings.

10
3.3.1 Measurement table for lower bearing assembly 3.3.2 Measurement table for upper wire
terminal
Wire dim. DD DH DW TED TET
Ø 4
Ø 120
~ 100 60 Ø 8.2 4
Ø 5 ~ 100 Ø 10.2 4.5
Fig. 3.3.a Fig. 3.3.b
TED
TET
An extended link/toggle does not give the required flexibility. It must always be
connected to the boat’s forestay fitting via a toggle.
Make sure that the toggles’
split pins are secure after
installation, see fig. 3.3.c.
Fig. 3.3.c
20°
DD
DW
DH

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3.3.3 Measurement table for toggles
(Toggles can be supplied by a Furlex dealer)
Toggle type
Forestay Dimension
Ø 4 Ø 5
Eye / fork toggle Part no. 174-102 174-103
Length (H) 25 35
Ø Eye (D1) 8 10
Ø Clevis pin (D2) 8 9.5
Fork width (W2) 8 10
Fork / fork toggle Part no. 517-056-02 517-054-02
Length (H) 25 30
Ø Clevis pin (D1) 8 10
Fork width (W1) 7.5 10
Ø Clevis pin (D2) 8 10
Fork width (W2) 8.5 11
T / fork toggle Part no. 174-127 174-128
Length (H) 60 70
Ø Clevis pin (D2) 8 9.5
Fork width (W2) 8 10
Stem ball / Eye toggle
+ fork/fork toggle. Part no. - 517-065-01
Length (H) - 138
Ø Stem ball (D1) - 26
Height (HB) - 8.5
Radius (R) - 10
Ø Clevis pin (D2) - 10
Fork width (W2) - 11
Fig. 3.3.g
H
D2
W2
Fig. 3.3.e
H
D2
W2
D1
Fig. 3.3.f
D2
W2
H
D1
W1
Fig. 3.3.h
W2
HB
H
R
D1
D2

12
3.4 Assembly below deck
The lower bearing assembly can be mounted in an anchor well below deck.
The advantage is that the sail’s luff length is maximized and the access around the forestay is improved.
The disadvantage is that routing of the furling line is more complicated, which increases friction when
furling and unfurling. A few different installation sketches are shown below.
There must be at least 250 mm to the furling line’s first turning, to ensure that the line is rolled up
evenly on the line drum.
The sail tack should be as close to the deck as possible.
There must always be some space between the Furlex system and the cut-out in the deck, inde-
pendent of whichalternative is chosen.
It is best to use ball bearing blocks with large sheaves to reduce frictional losses.
The anchor well must be effectively drained.
The Furlex system must never touch the edge of the deck cut-out during sailing. This is
to avoid damage to the boat and the Furlex system.
Line drum upper edge at deck level.
Requires a cut out in the deck for the
entire line drum. The furling line is lead
aft via lead blocks and a deck sheave
box.
Sail tack at deck level.
Requires a smaller cut out in the deck.
The furling line is lead first forward via
a deck sheave box, or alternately aft via
a block + a deck sheave box.
Lower bearing assembly mounted at
bottom of anchor box. Extended webbing
band with loop around the extrusion.
Can expose the luff extrusion to excessive
stresses.
Fig. 3.4.a
Fig. 3.4.b
Fig. 3.4.c.

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Existing forestay length (FL) without preload, incl. any rigging screw
(See fig. 3.5.a)
FL
=
Your
stay
Example
Ø 5
Calculation Table 1: Forestay wire length
3.5.1
T
H
WL
Deduction for lower wire terminal:
4 mm Ø wire: – 45 mm
5 mm Ø wire: – 55 mm
If a link or extra toggles are to be used, their length (H)
should be subtracted from FL.
Cutting length. The new forestay wire is marked at this measurement.
-- 190
= 13100
9,675
55
9,620
Lower bearing assembly mounted above the deck
forestay attachment in the anchor box.
For large distances, make a special stay from stain-
less strip or rod. Always connect to the boat’s forestay
attachment via a fork/fork toggle. Short wire pendants
are not recommended since they can distribute the fore-
stay forces unevenly due to the different cable strands.
Also, wires are not suitable for withstanding the torque
that can be produced.
3.5 Calculation of forestay wire length
1. Determine the rake of the mast with the fore-/backstay tensioned
2. Slacken the backstay. The setting of any forestay rigging screw should not be adjusted. If the forestay
rigging screw has to be adjusted, measure the length or mark the original setting with tape before
adjusting.
3. Pull the masthead forward using the genoa halyard. Secure the halyard using a “D” shackle or tie it
to a strong deck fitting. For safety reasons, do not use the halyard snap shackle.
Always use a strong “D” shackle or tie the halyard!
4. Take down the forestay. (If the rigging screw was adjusted, return it to its original setting.)
5. Measure the forestay length (FL) with just enough tension to keep it straight.
6. Enter the measurement in “Calculation Table 1” below, under the heading “Your forestay”, on the
row marked FL.
7. Calculate the new wire length WL in “Calculation Table 1”. Refer to the column marked “example”
to see how this is done.
Fig. 3.4.d.
-- 190

14
WL
New forestay wire length (according to “Calculation table 1”)
If the top extrusion is shorter than 400 mm (15 3/4”), the joint
will be too near the top. In this case replace the uppermost full-
length 2400 mm extrusion with the 2000 mm (78 3/4”) extrusion.
In this way the joint is moved 400 mm. Adjust the C and D
measurements as follows:
• Reduce the C-measurement by 400 mm.
• Increase the D-measurement by 400 mm.
-
3.6 Calculating the length of the luff extrusion
1. Insert the length of the new wire forestay (WL) as calculated in “Calculation Table 1”
in “Calculation Table 2”, in the row marked WL.
2. Calculate the number of full-length extrusions and the length of the top extrusion.
Fixed deduction (A+B):
C+D=
3.6.1
A+B
C+D
C
D
Max. number of 2400 mm (94 1/2”) extrusions which together
are shorter than C+D: [ ............ x 2400 = C ] C=
Length of top extrusion =
The top extrusion is normally cut from the 2000 mm (78 3/4”)
extrusion. Round the edges of the cut end using a file.
4 mm Ø wire: E = D – 120 mm
5 mm Ø wire: E = D – 120 mm
Cut the distance tube for the top extrusion in accordance with
the following fixed deduction:
E
Deduction:
Length of distance tube E =
-
=
Calculation Table 2: Length of luff extrusion Your
extrusion
Example
Ø5
=
9,620
--1395
=1395
-1395 (3 extrusions)
-
=
=2115
=
4 mm Ø wire: – 855 mm
5 mm Ø wire: – 855 mm
855
8,765
7,200
1,565
120
1,445

15
Fig. 3.5.a
FL = Existing forestay length
A
E
CB
D
WL T

16
1.
Fit the long connecting plate (L=80 mm) in the 600 mm extrusion together with the join sleeve and
distance tube.
2.
Remove the join sleeve from a 2400 mm extrusion (this joining sleeve will later on be used for
the top extrusion). Connect a 2400 mm extrusion to the connecting plate in the 600 mm profile.
Push the distance tube fully into the 600 mm extrusion so that the join sleeve enters the 2400 mm
extrusion. See fig. 4.1.c.
3.
Connect the remaining extrusions according to table 3.6.1. Check with a join sleeve that the
distance tube is pushed about 100 mm (half the length of the join sleeve) into the extrusion. The
distance tube (E) in the top profile (D) should be pressed in about 20 mm.
Fig. 4.1.a
Fig. 4.1.c
4 Assembly of the Furlex-system
4.1 Assembly of the luff extrusion
Assembly should be carried out on a horizontal surface.
Connect the extrusions after each other starting with the lower bearing assembly.
Fig. 4.1.b
~ 100 mm

17
2. Measure the wire from the middle of the hole in the end. Mark the cutting size WL on the wire
accurately, with a marker pen. (the WL measurement was calculated in ”Calculation table 1”,
see chap. 3.5.1.)
3. The wire has a burnt, conical cut which simplifies later assembly into the extrusion. So do not
cut the wire yet.
4.
Unscrew the eye, wedge and former from the terminal.
5. Thread the wire through the luff extrusion from the upper end until the wire termination eye
stops against the extrusion top guard. If the wire jams inside the extrusion, turn it clockwise past
the obstacle. Temporarily hold top eye in place with tape.
6. Apply tape on both sides of the cutting mark, to simplify cutting. Check that the measurement
between the cutting mark and terminal is ~ 40 mm
7. Cut the wire. Deburr the end with a file.
8.
Turn the strands of the wire (clockwise seen from below) and insert the wedge.
Eye Former
Wedge
Fig. 4.2.a
Fig. 4.2.c
4.2 Wire assembly
NOTE! Take care when opening the roll of wire!
Fig. 4.1.e
4.
Push the lower bearing assembly onto the extrusion and assemble the screw through the recess
of the extrusion. Tighten the screw so that the extrusion is clamped in place. Push the halyard
swivel all the way down to the sail feeder area. Secure it in this position with adhesive tape. Feed
the top guard onto the top extrusion and fix it with the prefitted screw. Tighten the screw until it
bottom, but do not over-tighten.
1. Stretch the Furlex wire out by hand, on a flat surface.
Take care, since the roll of wire can spring apart when it is opened.
1

18
9.
The strands of the wire should protrude approx 2 mm from the wedge. Spread the outer strands of
the wire evenly around the wedge. Press the wire/wedge into the fixed part, so that the strands are
held in place. Tap lightly on the wire so that the outer strands are wedged firmly in place.
10. Bend the outer strands outwards slightly. Use polygrip pliers or tap the strands with a small ham-
mer. In the latter case, a counterhold is required e.g. a wooden block that will not damage the
terminal threads.
11.
Fit the former in the threaded hole of the eye. Lubricate the socket´s thread with a long bead of
locking adhesive. Then screw on the terminal part and tighten carefully with adjustable spanners
so that the wire is forced into the socket and the outer strands are bent inwards by the wedge.
12.
Unscrew and check that the outer strands are evenly spread around the cone.
If one strand lies over another, bend it back in place.
13. If the assembly has not succeeded and must be repeated, See ”Dismantling of Furlex”, chap.
17 in suitable parts.
14.
Apply 2-3 drops of locking adhesive on the thread and screw the terminal together again. Tighten it
securely. This is now permanently locked. Remove the tape holding the top eye.
Fig. 4.2.d
Fig. 4.2.f
Fig. 4.2.e
Fig. 4.2.g
2 mm
NOTE! Make sure there is no strand of the wire in the slot of the wedge!
NOTE! Make sure there is no strand of the wire in the slot of the wedge!

19
1.
Feed the furling line through the hole in the line guide fitting and then through the hole in the line
drum’s lower flange. Undo the self-tapping screw.
2.
Place the end of the line in the recess on the underside of the drum. Tighten the screw through the
line and into the drum. The head of the screw should be at the same level as the drum.
15.
Hook the lower edge of the sail feeder in the extrusion and push it up against the joint sleeve. Press
the connecting piece on from the front. NOTE, the marking“UP” on the connecting piece.
16. We recommend fitting the Furlex system onto the boat at this stage. See chapter 16 "Rigging".
Assembly of sail feeder:
Fig. 4.2.i Fig. 4.2.j
4.3 Fitting the line
Fig. 4.3.a
Fig. 4.3.b

20
1.
Put the line guard over the wire terminal and position the
locking block from the opposite side. Note the “UP” mark
on the locking block.
2.
Undo screw a few turns. Fasten the line guide fitting in the line guard and bring up toward the
stainless housing. Tighten the screws . Tighten the screw loosely against the locking block.
3.
Adjust the line guard vertically so that it is midway between
the line drum flanges. If the casing or line guard come into
contact with the line drum flanges, unnecessary friction will
be caused.
4.
Adjust the alignment of the line guide towards the lead
block and tighten screw . (See also “Furling line
arrangement”, chap. 6.3.)
Fig. 4.3.c
Fig. 4.3.e
Fig. 4.3.d
Fig. 4.3.f
=
=
1
2
4.4 Fitting the line guard and line guide fitting