Selden Furlex 400 S Supplement

Manual for assembly
and operation
Furlex 400 S & 500 S
595-116-E
2010-03-08
400 S & 500 S

2
This information must be followed to avoid damage to the system and the risk of
personal injury. The 5-year guarantee on the Furlex-system is only valid if the
system is assembled and operated correctly according to the manual.
Allen SocketSkrew Size Torx Socket
M 6
M10
M12
1 Introduction
PLEASE read the entire manual prior to assembly!
Seldén Mast AB guarantees the Furlex-system for 5 years. The guarantee covers faults arising from
defective design, materials or workmanship.
The guarantee is only valid if the Furlex-system is assembled, operated and maintained in accordance
with this manual and is not subjected to loads in excess of those indicated in the brochure and
instructions.
If the system is repaired by anyone other than Seldén Mast AB or one of our authorized dealers, the
guarantee ceases to be valid.
Seldén Mast AB reserves the right to alter the content and design without prior warning.
T 30
–
–Fig. 1.1.a
–
8 mm (5/16”)
10 mm (3/8”) Fig. 1.1.b
1.1 The manual
To derive the maximum benefit and enjoyment from your Furlex-system, we recommend that you
study this manual carefully.
The manual is divided into two sections, one dealing with ASSEMBLY and one with
OPERATION. Each section contains references to the other.
It is very important to read and note these cross references.
All safety-related information is indicated by the following symbol:
The manual covers two different Furlex sizes, 400 S and 500 S. The Furlex 400 S is designed for
use with a 12 or 14 mm forestay, while the 500 S system is designed for a 16 mm forestay and has
a stronger luff extrusion and halyard swivel.
The assembly procedure for the 400 S and 500 S differs in some respects. These differences are
indicated in the manual.
The size is marked on the line drum top.
Furlex is specified and manufactured using Metric dimensions. To assist owners unfamiliar with
this system, the approximate equivalent Imperial dimensions are given in brackets.
The screws used for the halyard swivel and lower bearing assembly have a Torx or Allen socket.
The requisite bits are included with the Furlex. The table below gives the relevant screw sizes and
corresponding sockets.

3
Page
1 Introduction
1.1 The manual 2
1.2 Product information 4
ASSEMBLY
2 Checklist
2.1 Furlex box 6
2.2 Foil pack 8
2.3 Tools 8
3 Assembly preparations
3.1 Forestay attachment - guiding principle 9
3.2 Mast attachment 9
3.3 Deck attachment 9
3.3.1 Dimensions of lower bearing assembly 10
3.3.2 Dimensions of top eye terminal 10
3.3.3 Table of measurements for toggles 11
3.4 Assembly below deck 12
3.5 Calculating the length of the forestay wire 13
3.5.1 Table 1: Calculation of forestay wire length 13
3.6 Calculating the length of the luff extrusion 14
3.6.1 Table 2: Calculation of luff extrusion length 14
4 Assembly of the Furlex-system
4.1 Assembly of the luff section 16
4.2 Fitting the wire terminal (or rigging screw) 18
4.2.1 Without rigging screw/With rigging screw 18
4.3 Fitting the line drum and line guide 21
5 Halyard routing
5.1.1 Halyard leads (only Furlex 400 S) 23
5.1.2 Halyard routing – Furlex 500 S 23
5.2 Halyard sheave box 24
5.2.1 Sheave boxes 24
5.3 Spinnaker halyard 24
5.4 Fitting the halyard lead (only 400 S) 24
6 Furling line arrangement
6.1 Functional description 26
6.2 Winding the line onto the drum 26
6.3 Routing of the furling line 27
6.4 400 S: Fitting the stanchion blocks 28
7 The Sail
7.1 Adapting the sail to the Furlex-system 29
7.1.1 Table of sail measurements 30
7.2 Sail shape 30
7.3 Determining the length of the pendant 31
Page
OPERATING MANUAL 32
10 Halyard routing
10.1 Summary 33
10.2 Halyard sheave box 34
10.3 Spinnaker halyard 34
11 Sailing with Furlex
11.1 To hoist the sail 35
11.2 Unfurling the sail 36
11.3 Furling the sail 37
12 Reefing
12.1 Free turn 38
12.2 Reefing under sail 38
12.3 Setting a reefed sail from the furled position 39
12.4 Adjusting the sheeting position 39
13 Furlex for racing 40
14 Adjusting the forestay length
14.1 Furlex with rigging screw 41
14.1.1 Rigging Screw adjustment 42
14.2 Furlex without rigging screw 42
15 Maintenance of the Furlex-system
15.1 Lubricating the lower bearing assembly 43
15.2 Lubricating the halyard swivel 43
15.3 Cleaning the Furlex 44
15.4 Storage 44
16 Rigging
16.1 Fitting the Furlex on a stepped mast 45
16.2 Stepping the mast with Furlex fitted 46
17 Dismantling
17.1 Halyard swivel 46
17.2 400 S: Sail feeder 46
17.3 Lineguide 47
17.4 Line drum 48
17.5 Lower bearing assembly 48
17.6 Wire terminal 49
17.7 Luff extrusion system 49
18 Trouble shooting 50
19 Checklist
19.1 Points to check before sailing 52
Contents

4
When the original Furlex was introduced in 1983, it was not a pioneering project. The design included
features which improved on other manufacturers’ products to increase performance, function and
reliability. The first systems sold are still functioning well, providing ample proof of the design’s
effectiveness and long-term staying power. Furlex quickly became the market leader, a position it
still occupies today. 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 a function of its displacement, ballast, beam
and draft. 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.
Furlex is only sold through authorized local dealers who are able to cover all service requirements for
the customer, including assistance with assembly, the modification of sails or the production of new
sails.
This new Furlex model range incorporates improvements based on our extensive experience, and
represents the very latest development of the jib furling and reefing concept.
Furlex is supplied as a complete assembly kit containing all the components required.
The ball-bearing system of the halyard swivel features a load distribution facility, a unique
patented system which distributes loads over the entire ball race. This permits smoother furling
and considerably reduces bearing wear.
Furlex can be supplied with an optional integral rigging screw.
The Furlex luff section has the same dimensions over its whole length. The entire luff is furled
in an even roll, right down to the tack of the sail. This is a requirement for satisfactory sail shape
when reefed.
The tack ring’s ”free turn” flattens out the sail, promoting an efficient shape when reefed.
Furlex is suited to both cruising and racing. The line drum and line guide are easy to remove if
you want to utilize the entire forestay length for racing.
The luff section has two luff grooves, allowing two jibs to be goose-winged when running down-
wind and facilitating fast sail changes for racing yachtsmen.
The prefeeder is always on hand to help when hoisting the sail.
The aluminium extrusion is insulated from the forestay over its whole length.The joining
sleeves of the Furlex 400 S are insulated internally to prevent wear and corrosion. The clearance
between the forestay and the joining sleeve on the 500 S is sufficiently large to be able to omit the
insulation.
The line guide fitting centres the line as it is wound onto the drum, and the flexible internal line
guard maintains light pressure on the line to ensure even distribution on the drum.
Furlex is manufactured by Seldén Mast, the world’s leading manufacturer of masts and rigging
systems.
1.2 Product information
Follow the instructions carefully when fitting.

5
3
1
2
5
10
11
8
4
6
7
9
19
18
20
22
21
12
13
14
15
16
17
4
1. Forestay eye terminal
2. Top guard
3. Halyard swivel
4. Snap shackle/D-shackle
5. Luff extrusion
6. Distance tube
7. Joining sleeve
8. Long joining sleeve
9. Sail feeder
10. Sail feeder connector
11. Connecting plate
12. Lower bearing assembly
13. Tack ring
14. Adapter
15. Terminal part or
rigging screw
16. Fork / fork toggle
17. Line drum half
18. Line guard housing
19. Line guard
20. Line guard bracket
21. Line guide fitting
22. Locking block

6
Lower bearing assembly with
tack shackle
400 S/Ø12
Rigging screw adapter
Forestay wire with top bearing
Wire terminal or Furlex rigging screw.
(Depends on which type ordered.)
Halyard swivel with head shackle
Two line drum halves
Line guide fitting
2 Checklist
2.1 Furlex box
ASSEMBLY

7
500 S:
Halyard leads are not included. A halyard
sheave box must be used for this model.
See Chap. 5.2, Fig. 5.2.a, page 24.
400 S:
2 halyard leads 508-128 with insulator
sheets incl. 6 screws
Drill bit Ø 5,3 mm (7/32”)
Furling line
Torx bit set (T15/20/25/30/40/45)
400 S & 500 S
6 stanchion blocks 538-210-01
Locking adhesive
Lubricating grease
Top guard incl. 4 screws
Pree-feeder with rope
Instructions
Spare parts list
Certificate of guarantee
Line guard housing
Line guide locking block

8
400 S: One short connecting plate for each
2400 mm (94 1/2”) luff extrusion
400 S: One long connecting plate
(for sail feeder)
500 S: One short connecting plate for each
4800 mm (189”) luff extrusion
Tools needed for assembly:
Screwdriver (standard tip)
Screwdriver for 1/4”
Hacksaw
2 adjustable spanners
Pair of pliers (“Polygrip”)
Adhesive tape
File
Marker pen (water-proof)
Torx bits (included in Furlex package)
Allen keys (included in Furlex package)
Steel measuring tape (30 m) (100”)
Knife
Allen keys 8 (5/16”) and 10 mm (3/8”)
2.3 Tools
One 1000 mm (39 3/8”) luff extrusion with
long joining sleeve
+ bearing plug with bushes
400 S: One 1700 mm (67”) luff extrusion
with distance tube.
500 S: One 2000 mm (78 3/4”) luff
extrusion with distance tube.
400 S: 2400 mm (94 1/2”) luff extrusions
with distance tube + joining sleeve (number
dependent on length ordered.)
500 S: 4800 mm (189”) luff extrusions with
distance tube + joining sleeve (number
dependent on length ordered.)
400 S: Sail feeder
(Sail feeder + sailfeeder connector.)
500 S: The sail feeder is cut into the 1000
mm luff extrusion on this model.
2.2 Foil pack
400 S:
For halyard leads:
Heavy-duty Philips screwdriver
Drill
Drill bit Ø 5.3 mm (7/32”)
(included in package)

9
Forestay attachment on masthead rigs: Always
connect the stay with a toggle to give full
articulation.
Forestay attachment on fractional rigs, Seldén
type:
Connect to existing toggle.
Fig. 3.2.a Fig. 3.2.b
FL
H
FL
3 Assembly preparations
3.1 Forestay attachment - guiding principle
3.2 Mast attachment
Some Seldén forestay attachment options are shown below, illustrating the rules and exceptions.
For H dimensions, 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 attachments.
3.3 Deck attachment
The lower end of the Furlex-system is fitted with a fork toggle as standard. This can normally be
attached directly to the boat’s forestay fitting at the stemhead.
Check that the lower bearing assembly and line guide do not interfere with the pulpit, navigation
lights or other deck fittings.

10
500 S
220 (8 5/8”)Ø 250 (9 7/8”)
400 S
Furlex Serie
140 (5 1/2”)220 (8 5/8”)
Wire Dim.
If the boat is fitted with a bow anchor, it may
be necessary to permanently raise the lower
bearing assembly to give the crew sufficient
space for anchor work. A selection of extension
links are available (see Table 3.3.3).
If the lower bearing assembly is raised by
means of an extension link, a Furlex toggle or
similar toggle with the same function should be
fitted between the link and the boat’s forestay
attachment.
Fig. 3.3.c
If a custom made extension link is used it must always have a toggle between it and the
boat´s forestay attachment.
3.3.1 Dimensions of lower bearing assembly (mm) 3.3.2 Dimensions of top eye terminal
DD TETDWDH TED
Ø 12 (15/32”)
Ø 14 (9/16”)
Ø 16 (5/8”)140 (5 1/2”)
20 (25/32”)
23 (29/32”)
25 (63/64”)
15 (19/32”)
17 (43/64”)
24 (15/16”)
Ø 250 (9 7/8”)
Fig. 3.3.a Fig. 3.3.b
DD
DW
DH
TED
TET
Take care to ensure that the toggle
split pins are secured as per fig.
3.3.d after fitting.
Fig. 3.3.d
20°

10 11
Toggle type
Forestay Dimensions
Ø 12 Ø 14 Ø 16
Article no. 174-125-01 174-133-01 174-126-01
Length (H) 95 (3 3/4”) 95 (3 3/4”) 120 (4 3/4”)
Ø Eye (D1) 20 (25/32”) 20 (25/32”) 23 (29/32”)
Ø Clevis pin (D2) 19 (3/4”) 19 (3/4”) 22 (7/8”)
Fork width (W2) 22 (7/8”) 22 (7/8”) 25 (63/64”)
Article no. 517-052-02 517-053-02 517-074-02
Length (H) 65 (2 9/16”) 80 (3 5/32”) 85 (3 11/32”)
Ø Clevis pin (D1) 19 (3/4”) 22 (7/8”) 25 (63/64”)
Fork width (W1) 20.5 (13/16”) 20.5 (13/16”) 22 (7/8”)
Ø Clevis pin (D2) 19 (3/4”) 22 (7/8”) 22 (7/8”)
Fork width (W2) 21 (13/16”) 23 (29/32”) 26 (1 1/32”)
Article no. 517-069-01 - -
Length (H) 226 (8 7/8”) - -
Ø Stemball (D1) 34 (1 11/32”) - -
Height (HB) 8.5 (11/32”) - -
Radius (R) 15 (19/32”) - -
Ø Clevis pin (D2) 19 (3/4”) - -
Fork width (W2) 21 (13/16”) - -
Article no. 517-075-01 517-076-01
Length (H) 190 (7 1/2”) 190 (7 1/2”)
Ø Clevis pin (D1) 19 (3/4”) 22 (7/8”)
Fork width (W1) 20.5 (13/16”) 20.5 (13/16”)
Ø Eye (D2) 20 (25/32”) 22.5 (7/8”)
Gauge (W2) 12 (15/32”) 16 (5/8”)
Eye / Fork-toggle
3.3.3 Table of measurements for toggles
(Toggles available from your Furlex dealer)
Fig. 3.3.e
Fig. 3.3.f
Fork / Fork toggle
Fig. 3.3.g
H
D2
W2
D1
D2
W2
H
D1
W1
Stemball / Eye toggle
with Fork / fork toggle
Eye / fork Extension link
Fig. 3.3.i
D2
H
W2
D1
W1
500 S Custom made
extension link. (Not available from
Seldén Mast AB).
Specification: Fig. 3.3.j
Material: AISI 316 or equivalent. Preferably
electro polish after machining.
Connection: Attache to the lower bearing
assembly´s toggle, and to deck via a sepa-
rate toggle. Seldén Furlex toggle
517-074-02 is available from your Furlex
dealer.
2x10 mm
(2 x 3/8”)
Existing toggle
517-074-02
Furlex toggle
517-074-02
60 mm
(2 3/8”)
35 mm (1 3/8”)
35 mm (1 3/8”)
Custom length
Hole Ø 22,5 mm
(7/8”)
Hole Ø 26 mm (1 1/32”)
W2
HB
H
R
D1
D2

12
Top edge of drum at deck level.
Large deck hole required for line drum.
Furling line led aft via turning block and
inset deck sheave box, then aft along the
deck.
Tack snap shackle at deck level.
Requires smaller hole in deck.
Furling line leads forward to an inset deck
sheave box, alternatively aft via a block +
deck sheave box.
Lower bearing assembly in the bottom of the
anchor well. Long webbing band attached
around the extrusion.
May put too much strain on the furling
extrusion.
Fig. 3.4.a
Fig. 3.4.b
Fig. 3.4.c.
3.4 Assembly below deck
The lower bearing assembly can be fitted below deck inside an anchor well.
The advantage is that the sail’s luff length is maximized and the access around the forestay is improved.
The disadvantage is a more complicated route for the furling line, increasing furling resistance. The
diagrams below illustrate various methods of installation.
For the furling line to be wound evenly onto the line drum, the first turning point must be at least
500 mm (19 11/16”) away.
The tack should be located as close to deck level as possible.
Regardless of which option is chosen, the Furlex-system must always be kept clear of the deck
well’s inside surfaces.
Avoid routing the line through an integral deck conduit, as this will increase the friction on the
furling line.
Use a large ball-bearing block to minimize friction losses.
The anchor well must be well drained.
To avoid damage to the Furlex-system and the boat, the system must never be allowed
to come into contact with the edge of the deck or well when sailing.

13
T
FL
With rigging screw:
(Riggingscrew 50% extended.
Adjustable ±50 mm)
Existing forestay length (FL), including rigging screw
(See Fig. 3.5.a)
Without rigging screw:
Cutting measurement. The new forestay wire is to be marked
at this point.
Ø 12 mm wire: 190 mm (7 31/64”)
Ø 14 mm wire: 190 mm (7 31/64”)
If links or extra toggles are to be used, deduct this length (H) from FL.
(See table 3.3.3.)
=
Furlex fitted above deck, but with the forestay fitting in the
anchor well.
Use a Furlex extension link (not 500 S). For a larger gap, (or
for 500 S,) use a custom made stainless steel bar or rod stay.
See specifications on page 11.
Short wire pendants are not recommended as forestay forces
may not be distributed evenly, and wire will not resist the
torque which may be produced.
3.5 Calculating the length of the forestay wire
1. Determine the rake of the mast with the fore-/backstay tensioned.
2. Slacken the backstay as much as possible, but make sure that any rigging screw is not unscrewed so
far that the threads are no longer visible ”on the inside”. The forestay setting should not be adjusted.
If there is insufficient adjustment in the backstay, and the forestay must be adjusted to allow removal,
first mark its thread with adhesive tape.
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 it was slackened, adjust the rigging screw back to the tape marks.
5. Measure the forestay length (FL) with just enough tension to keep it straight.
6. Enter the measurement in ”Table 1” below, under the heading ”Your forestay”, in the row
marked FL.
7. Calculate the new wire length WL in Table 1. Refer to the column marked “example” to see how
this is done.
Your
forestay
Example
(400 S/Ø14)
with rigging screw
50% extended
H
WL
Deduction for lower wire terminal:
400 S
500 S
Ø 12 mm wire: 325 mm (12 13/16”)
Ø 14 mm wire: 325 mm (12 13/16”)
-- 190
=13100
Fig. 3.4.d.
18.000
325
17.675
Ø 16 mm wire: 190 mm (7 31/64”) Ø 16 mm wire: 325 mm (12 13/16”)
Table1: Calculation of forestay wire length
3.5.1

14
Length of distance tube E =
If the top extrusion is shorter than 700 mm (27 9/16”) (500 S: 1000 mm (39
3/8”)), the joint will be too near the top. In this case replace the uppermost
full length 2400 mm extrusion (500 S: 4800 mm) with the 1700 mm (500 S
2000 mm (78 3/4”)) extrusion. In this way the joint is moved 700 mm (27
9/16”) (500 S: 2800 mm (110 1/4”)) down the stay. Adjust the C and D
measurements as follows: Deduct 700 mm (27 9/16”) (500 S: 2800 mm (110
1/4”)) from the C measurement.
Add 700 mm (27 9/16”) (500 S: 2800 mm (110 1/4”)) to the D measurement.
(6 profiler)
-
3.6.1
540
1.355
500 S
C
17.675
1.380
16.295
14.400
1.895
Table 2: Calculation of luff extrusion length
Length of new forestay wire (as per Table 1)
Deduction: -
3.6 Calculating the length of the luff extrusion
1. Insert the length of the new forestay wire (WL) as calculated in ”Table 1” into ”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=
WL
A+B
C+D
400 S
C
D
Max. number of 2400 mm (94 1/2”) extrusions which together are
shorter than C+D: [ ............ex x 2400 = C ] C=
Length of top extrusion =
The top extrusion is normally cut from the 1700 mm (67”) (500 S: 2000 mm (78
3/4”)) extrusion. Round the edges of the cut end using a file.
Cut the distance tube for the top extrusion in accordance with
the following fixed deduction:
E
-
=
Your
extrusion
Example
(400 S/Ø14)
with rigging screw
--1395
=1395
-1395
Max. number of 4800 mm (189”) extrusions which together are
shorter than C+D: [ ............ex x 4800 = C ] C= -1395
==2115
=
Without rigging screw:
Ø12 mm wire: 1450 mm (57 1/16”)
Ø14 mm wire: 1470 mm (57 7/8”)
Ø16 mm wire: 1395 mm (54 15/16”)
With rigging screw:
(with rigging screw 50% extended
adjustable ± 50 mm (2”) )
400 S
500 S
Ø12 mm wire: 1340 mm (52 3/4”)
Ø14 mm wire: 1380 mm (54 5/16”)
Ø16 mm wire: 1310 mm (51 9/16”)
Ø12 mm wire: E=D –510 mm (20”)
Ø14 mm wire: E=D –560 mm (22 1/8”)
Without rigging screw:
With rigging screw:
(with rigging screw 50% extended
adjustable ± 50 mm (2”))
400 S
500 S
Ø12 mm wire: E=D –495 mm (19 1/2”)
Ø14 mm wire: E=D –540 mm (21 1/4”)
Ø16 mm wire: E=D –570 mm (22 7/16”) Ø16 mm wire: E=D –545 mm (21 7/16”)

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

16
4 Assembly of the Furlex-system
4.1 Assembly of the luff section
The assembly procedure for the 400 S luff section is described below. Assembly of the 500 S luff
section differs from the 400 S in the following respects:
The sail feeder of the 500 S is not a separate component, as shown in fig. 4.1.b, but is cut into the
1000 mm (39 3/8”) luff extrusion.
The 500 S has two-part distance tubes, which are fitted in the same manner as on the 400 S.
The 500 S has 4800 mm (189”) luff extrusions instead of 2400 mm (94 1/2”) extrusions as on the 400 S.
Assembly should be carried out on a horizontal surface. Connect the luff extrusions one by one as
follows:
Fit the long joining sleeve at the same time as the long connecting plate into a 2400 mm (94 1/2”)
luff extrusion and guide the sail feeder on.
Insert a distance tube (L = 2100 mm (82 11/16”)) and push the joining sleeve until it lies flush with
the lower edge of the sail feeder.
Fit the 1000 mm (39 3/8”) luff extrusion onto the connecting plate.
Push the distance tube until
the long joining sleeve touches the 1000 mm
(39 3/8”) luff extrusion. Use a short joining sleeve to push the
distance tube down the last part of the way. Check that the distance (J) between the end of the
distance tube and the end of the extrusion is approximately half the length of the joining sleeve.
Fig. 4.1.a
Fig. 4.1.b
Fig. 4.1.c
Fig. 4.1.d
1.
2.
3.
4.
J

17
Fit a joining sleeve into the next 2400 mm
(94 1/2”) extrusion together with a connecting plate. Connect this to the lower extrusions.
Using a spare joining sleeve, push in the distance tube from the top until the lower joining sleeve
touches the distance tube below the join. Check that the distance (J) between the end of the
distance tube and the end of the extrusion is approximately half the length of a joining sleeve.
Connect the remaining extrusions according to ”Table 2” (3.6.1).
Fit the halyard swivel over the top end of the extrusion, slide it down as far as the sail feeder and
secure it in this position with adhesive tape. Fit the top guard and secure it with the four pre-fitted
screws. Tighten the screws until they bottom, but do not over-tighten.
Guide the lower bearing assembly on from below. Push it carefully onto the extrusion so that the
stainless steel inner tube does not scratch the extrusion. Use cloth or paper for protection.
5.
6.
7.
8.
Fig. 4.1.e
Fig. 4.1.f
Fig. 4.1.h
J
Fig. 4.1.g 400 S Fig. 4.1.g 500 S

18
500 S
400 S
Ø 16 mm wire: c:a 240 mm (9 29/64”)
4.2.1 With rigging screw:
Ø 12 mm wire: c:a 340 mm (13 3/8”)
Without rigging screw:
Ø 12 mm wire: c:a 215 mm (8 15/32”)
Ø 14 mm wire: c:a 340 mm (13 3/8”) Ø 14 mm wire: c:a 230 mm (9 1/6”)
Ø 16 mm wire: c:a 345 mm (13 9/16”)
6. Cut the wire. Round the end of the wire using a file.
8.
Thread the socket onto the wire.
Fig. 4.2.a
Fig. 4.2.b
Former Wedge Socket
Terminal part (or rigging screw)
4.2 Fitting the wire terminal (or rigging screw)
1. Stretch the Furlex wire out by hand on a flat surface.
Be careful when you open the wire coil as it may uncoil quickly.
Note: Be careful when you open the wire coil!
2. Measure the wire from the centre of the hole in the terminal end fitting. Mark the measurement WL
carefully on the wire using a marker pen. (The WL measurement was calculated in ”Table 1”,
(Chapter 3.5.1.)
3. The wire is annealed and tapered, making it easier to fit into the extrusion. Do not cut the wire yet.
4. Feed the wire through the luff extrusions from the top until the eye of the end fitting stops against
the top guard. Secure it in this position with adhesive tape. If the wire catches inside the extrusion,
turn it counter-clockwise until it passes the obstruction.
5. Put adhesive tape around the wire on both sides of the cutting mark to assist cutting. Check that the
measurement between the cutting mark and the bottom edge of the 1000 mm (39 3/8”) extrusion is
as shown in the following table 4.2.1.
Unscrew the socket, wedge and former from the terminal part ( or Furlex rigging screw if to be
used.)
7.

19
9.
Slide the wedge over the core (7 strands) of the wire . The core of the wire should protrude approx.
3 mm (1/8”) from the wedge.
10.
Remove the adhesive tape from the top eye terminal. Space the outer
strands of the wire evenly around the wedge and bring down the
socket so that the strands are held in place. Hold an adjustable
spanner between the 1000 mm extrusion and the socket. Tapping the
core of the wire, locate it firmly in the socket.
Check that the core of the wire protrudes approx. 3 mm (1/8”)
from the wedge. See fig. 4.2.c.
11.
Bend the outer strands inwards a little using a pair of pliers,
or tap the strands with a small hammer. In the latter case,
rest the socket’s thread on a soft surface (wood or similar) to
prevent damage.
NOTE! Check that no strands slip into the slot of the wedge.
13.
Unscrew and check that the outer strands are
evenly distributed around the wedge. If some
strands are crossed, correct their positions.
NOTE! Check that no strand has slipped into the slot of the wedge!
14. If assembly is unsuccessful and needs to be repeated, refer to the relevant sections of Chapter 17,
”Dismantling the Furlex”.
Fig. 4.2.c
Fig. 4.2.d
Fig. 4.2.n
Fig. 4.2.e
15.
Apply another 2 or 3 drops of the locking
adhesive to the thread and screw the terminal
together, tightening it firmly. The terminal is
now permanently locked. Fig. 4.2.f
3 mm
12. Insert the former into the threaded hole of the terminal part (or rigging screw). Lubricate the
socket´s thread with a long bead of locking adhesive. Screw the terminal part onto the socket and
tighten carefully, forcing the wire further into the terminal.

20
Terminal part:
Guide the lower bearing assembly down over
the terminal part. The inside of the lower
bearing assembly matches the flat face on the
terminal part.
Furlex rigging screw 400 S wire Ø 14 and
500 S wire Ø 16:
Ensure that the flat surfaces of all three
components are aligned. The rigging screw has
an integral end stop to prevent it from being
completely unscrewed. Never try to adjust the
rigging screw past this point. Guide the lower
bearing assembly down over the Furlex rigging
screw. As the inside of the lower bearing assem-
bly matches the flat faces, it will securely lock
the rigging screw.
Adjust the position of the luff extrusion so that the
centre of the marking on one side of the extrusion
is aligned with the top edge of the adapter. Apply
2-3 drops of locking adhesive to the screws 
which fasten the lower bearing assembly to the luff
extrusion. Insert the screws into the adapter, ensuring
that they enter the holes in the luff extrusion. Use the
10 mm Allen key spanner enclosed in the set. Apply
locking adhesive on the screw. Tighten the screws
hard.
Fit the clevis pin and split
pin. The legs of the split pin
are only opened approx. 20°,
ensuring that the pin remains
intact on disassembly and
could be re-used.
21. We recommend fitting the Furlex-system onto the boat at this stage. (See Chapter 16, ”Rigging”.)
Fig. 4.2.g
Fig. 4.2.h
Fig. 4.2.i Fig. 4.2.j
Fig. 4.2.k
Fig. 4.2.l
2
2
20°
16. Check the length FL of the stay acc. ”Table 1” (3.5.1) & fig. 3.5.a. If the Furlex rigging screw is
fitted, it should be 50% extended. (”Rigging screw adjustment”, see table 14.1.1).
18.117
19.
20. 1
18.2
Only 400 S wire Ø 12 only with Furlex rigging screw
Ensure that the flat faces of the rigging screw are aligned.
The rigging screw has an integral stop to prevent it from
being completely unscrewed. Never try to adjust the
rigging screw past this point. Guide the adapter tube onto
the rigging screw and then guide the lower bearing assembly
down over this. The flat internal surface of the adapter tube matches
the rigging screw and its flat external surface matches the flat inner surface
of the lower bearing assembly, so that the components lock when assembled.