Trogear Bowsprit User manual

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Trogear SAS
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Trogear Bowsprit Through Hull Installaon Manual
Congratulaons on your purchase of the Trogear Bowsprit which can be installed on most sailboats. The through
hull installaon is not a complicated process, but it does require careful measurements. Please read the instrucons
thoroughly rst, and if in doubt contact us or your boat rigger with any quesons.
Keep in mind that these instrucons present the basic process. As each boat is designed dierently, your boat may
require specic installaon modicaons. Again, please consult your rigger if in any doubt, and you may decide that it is
best to have your rigger install the Bowsprit for you.
NOTE: If you are not able to install our bowsprit using this method, our side mounts or deck mounng soluon might be
right for your yacht. Custom opons are also possible and we can work with you to devise a suitable method for your
yacht. See our website or contact us for details.
Materials and Tools Required
Parts for the Adjustable Bobstay Aachment (not included )
●5/16 Dyneema (The bobstay purchase is 2:1. Measurements are specic to each boat)
●U Bolt for Bob stay aachment (consult your rigger or sailmaker to determine the working loads for your boat)
●Low fricon rings, Stainless steel rings or blocks
●Bungee cord (Recommended from Davis - MiniShockleTM)
●Preventer Dyneema (Safety feature)
●Masking Tape
●Marker or pencil
●Tape measure
●Drill motor
●Pilot drill bit and 1 inch drill bit
●Round or rotary le
●Structural Epoxy –West System Six10 or similar
●Isopropyl alcohol or acetone
●Vinyl gloves
●Paper towels
●Sandpaper grid 60
●Blue Locte
●Safety Goggles

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OVERVIEW
The bowsprit is aached to the boat via a removable sha connecng the bowsprit ends. The sha rotates
inside a transversely mounted Fiberglass tube
(Hinge tube).
The Hinge tube is permanently bonded to
the hull with structural epoxy such as West
System Six10 or equivalent. The installaon is
similar to other through hull installaons such
as depth sensors, through valves, etc.
In some cases, depending of the construcon
(cored hulls) or thickness of the hull, the
area surrounding the Hinge tube should be
reinforced by adding layers of Fiber Glass or
Marine Grade Plywood from inside. (Consult
your rigger or contact us if in doubt)
Due to the high compression forces that
the bowsprit can generate, each Hinge tube
end should not protrude past the hull more
than ¾”. If the hull is narrow, such as on a
trimaran, the Trogear Side Mounts or external structural spacers are a viable soluon. Please contact us with
any quesons.
Important: Before installing, do a dry t of the bowsprit. Be sure that the bowsprit can move up freely and
not hit the sides of the boat, bow roller or a rub rail if relevant. Addionally, be sure there are no obstrucons
below deck in the area.
(Fig. 1 & Fig 2)
Fig. 1: Inside the hull is clear Fig. 2: Inside the hull showing the Hinge Tube installed

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INSTALLATION PROCEDURE
A) Determine the Locaon of the Through Hull Holes for the Hinge Tube:
Note: Keep in mind that for the strongest aachment, the
posion of the tube should be as close to the deck hull
joint as possible. Make sure the Hinge tube is low enough
to not interfere with the deck.
1. First, determine the vercal distance from the deck
for the center of the Hinge tube hole. Place masking
tape below the deck on each side of the bow in the
area where the tube will be installed. This protects
the hull nish and is for temporary markings. (Fig. 3)
2. Horizontal locaon of the Hinge tube: Align the
Bowsprit symmetrically with the Bow and have
the ends touching the hull. Insert a marker in the
Bowsprit Sha aachment holes and mark the Hinge
tube locaons. (Fig. 4)
(This is best accomplished with a helper)
3. The locaon of the Port and Starboard hole should
be symmetrical. Check by comparing the distances
using a piece of non-stretching line aached to the
headstay or other method as appropriate. (Adjust
the hole center locaons if necessary) (Fig. 5)
Fig 3: Tape below the deck.
Fig 4: Use the Bowsprit to determine placement.
Fig 5: Using non-stretching line aached to the headstay, or other method as appropriate, check that the distances you marked are the same on
each side of the boat.

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B) Drilling Holes for the Hinge Tube:
NOTE: You may cover upholstery or other parts inside
against debris
1. First, drill a pilot hole through the hull on
each side. The hole should be horizontal and
perpendicular to the boat’s longitudinal axis.
(Fig. 6)
2. Next, using a 1” step drill, drill the holes for the
tube. (Fig. 7)
3. Fine-tune the holes with a rotary or round le
unl the Hinge Tube can be pushed through.
For the best results, the gap between the Hinge
tube and opening should be approximately
0.01”. (Fig. 8)
C) Bonding Hinge Tube to the Hull:
1. Mask area around the holes leaving about ¼ “ exposed
for epoxy llet. (Fig. 9)
2. Mask the Hinge tube ends to prevent the epoxy from
entering the tube. Clean area surrounding the drilled
holes and Hinge Tube ends with alcohol or acetone and
lightly sand with 60-grid sandpaper. Blow out the dust
and don’t touch.
3. For Yachts with cored hulls: reinforce the area by
removing at least ½” of core surrounding the hole and
lling it with West System 404 High Density Adhesive
Epoxy Filler or similar. Aer the epoxy cures, make sure
the tube will t and has a proper gap of approx. 0.01”.
Fine tune the hole as needed. (see B 3 above).
Fig 6: Drill a pilot hole rst.
Fig 7: Drill holes using a 1” step drill. Fig 8: ne tune holes with a rotary or round le.
Fig 9: Leave about ¼ “ exposed for epoxy llet.

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4. If for some reason the Gap between the Hinge tube and
Hull opening is too large (more than 0.05”): Mix epoxy and
completely coat the drilled holes, working the epoxy into the
surface. Aer the epoxy cures, trim any excess epoxy from the
holes with a round or rotary le. For the best results the gap
between the Hinge Tube and opening should be 0.01”
5. Applying Thickened Structural Epoxy onto the holes and
bonding the tube: Mix Epoxy and completely coat the drilled
holes, working the epoxy into the surface. Coat about 2” of
the Hinge Tube end and insert it into the previously coated
hole and slide it in about a half of its length. Next, also coat
about 2” of the protruding tube end and push and rotate the
tube at the same me unl it protrudes from the opposite
opening. Move and rotate the tube back and forth, and if
necessary add addional Epoxy, to make sure that there is a
proper bond without voids or gaps. (Fig. 10 ) Then, center the tube so that both ends protrude an equal distance
from the hull; you can form a llet around the tube/hull locaons at this me. (Fillets around the tube could be
added later once Epoxy cures). Remove the tape before the epoxy dries.
NOTE: There must be no voids or gaps between Hinge Tube and Hull.
D) Install a Bobstay U Bolt:
The Bobstay is aached on one end to the p of the
Bowsprit and is routed to a U Bolt aached to the bow.
To further decrease bobstay fricon during adjustment,
a low fricon ring can be inserted inside the U Bolt, as
shown here. (Fig. 11)
Select the U Bolt based on hull thickness and choose a Marine
grade Stainless Steel with minimum working load based on your
sails and intended bowsprit use. (Most boats should be ne with
5/16” U Bolts). The angle of the Bobstay is important. For a best
load distribuon, it should at least 45 deg. when the Bowsprit is in
a horizontal posion.
(IMPORTANT: Code 0 type sail generates forces on bobstay twice
as high as an Asymmetrical Spinnaker) – if in doubt, consult your
rigger or sail maker.
Install the U Bolt following the manufacturer’s instrucons.
E) Aaching the Bowsprit:
Note: This is best done with a helper but with a lile skill it
can be done alone too.
1. Align the Bowsprit tube end hole with the Hinge tube
hole and slide the Hinge sha into the tube. Use 5/16
bolts, threads coated with a blue Threadlocker or
equivalent and washers to secure it in place.
(Torque 130 in-lbs)
2. If the Bobstay rigging and Stop strap and Bungee are
not in place yet, temporarily secure the bowsprit in
place with a line. (Fig. 12)
Fig 10: Make sure that there is a proper bond without voids
or gaps.
Fig 11: U Bolt aached to the bow.
Fig 12: Temporarily secure the Bowsprit with a line

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F) Rigging the Bowsprit:
There are many ways to rig the Trogear Bowsprit. (For more rigging details, see our rigging example secon online).
1. Permanently Fixed Bowsprit:
The simplest rigging is when the Trogear Bowsprit is used in a permanently extended posion without the need for
adjustment. Use a xed length Bobstay with one end aached to the U Bolt and the other aached to the p of the
Bowsprit.
2. Adjustable Bowsprit – hinged aachment:
The Trogear bowsprit’s main design feature is the
hinged aachment, which allows it to rotate up and
down. We recommend a 2:1 Bobstay purchase with
the control line leading to a clutch and winch in the
cockpit. This allows you to take full advantage of
our unique design and adjust the sail lu tension
or bring the Bowsprit to an upright posion (for
stowing or changing sails only) (Fig. 13).
IMPORTANT NOTE: The Trogear Bowsprit should
be close to a horizontal posion when ying the
sails. See our use instrucons enclosed with your
purchase or online for more details.
A Bungee cord can be used to hold the Bowsprit in
an upright posion or pop it up when the bobstay is
released (similar in funcon to a Pole Topping li).
We recommend the MiniShockleTM from Davis but
others can be suitable as well. (Fig. 14)
Safety Measure: A method of prevenng the
bowsprit from pivong down past a predened
angle is needed in the event the sail drops to the
water.
Preventer Dyneema: The preventer should
be made from Dyneema and aached to the
headstay toggle and the lower fricon ring at the
p of the Bowpsprit. The length of the Dyneema
should be such that the sprit does not drop past
~20deg of horizontal when under tension. Think
of it as an inverted bobstay or a topping li on a
spinnaker pole. (Fig. 15)
See next page for more rigging details.
Fig 13: Bowsprit in upright posion to aach a furler.
Fig 14: Showing Bungee Cord and Stop Strap.
Fig 15: Preventer from Dyneema

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1. U Bolt (shown here with low fricon ring)
2. Bobstay Dyneema - 2:1 purchase
3. Low fricon ring
4. Stainless steel ring for furler aachment or with block for tack line
5. Dyneema loop lead through the bowsprit bushing connects stainless steel ring (#4) and low fricon ring (#3)
6. Bobstay control line led through a clutch to a winch in the cockpit.
7. Bungee cord
1. Furler aached to stainless steel ring.
2. Block for tack line
3. Bobstay Dyneema
Rigging Example: (each yacht owner can congure the rigging that is most suitable for their needs.)