Harken 1093 User Manual

Carbon

Jib Reefing & Furling

Installation Manual

Unit 2/2.5

TABLE OF CONTENTS

Parts 3

Pictures and list of all parts

Specifications 4

Rod sizes

Clevis pin sizes

Luff tape sizes

Rigging, attachment to lower unit

Retrofits, fitting rod

Tools required

Supplies for gluing foils

Alignment splints

Headstay length

Preparation for Assembly 5-6

Foil cut length

Top foil cut length

If you have a short top foil

Cutting top foil

Assembly 7-11

Sliding foils onto rod

Attaching feeder

Joining foils using connectors

Preparing foil for gluing

Gluing foils using Hysol® adhesive

Gluing feeder

Aligning joined foils

Sliding halyard swivel onto foils

Capping foils with trim cap

Removing splint

Installing Navtec® eye

Installing carbon furling unit

Assembling turnbuckle

Foil height

Commissioning 12-16

Tying soft attachment lines

Halyard wraps

Prevent halyard wraps

Pendants

Halyard restrainer

Halyard tension

Warranty

Warranty of Harken Carbon parts is

one year from the time of purchase.

2 2/2.5 Carbon Furler December 2001

PARTS

1

Toggle

*Cross pin includes (2) H2912A bushings.

(36) Connector bushings

Prefeeder

Cross pin*

Cotter pin

3 4

Smalley Ring

Clevis pin

Trim Cap

Bottom

(Feeder)

Connector

Halyard

Swivel

Regular Connectors

Torque Tube Connector

5

2

Top Bushing

Feeder

1

Prefeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947

Toggle . . . . . . . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . H-29364C

Toggle . . . . . . . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . H-27385C

Cross Pin . . . . . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . H-29388A

Cross Pin . . . . . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . H-27407A

Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HFG344

Smalley Rings . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . HCP1352

Smalley Rings . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . HCP1062

Clevis Pin . . . . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . H-29385A

Clevis Pin . . . . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . H-29386A

2

Bottom (Feeder) Connector. . . . . . . . . . . . . . . . . . . . . H-27448BF

Regular Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . 1096F

Top Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-27508BF

Torque Tube Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . H-27902BF

3

Connector Bushings (36) . . . . . . . . . . . . . . . . . . . . . . H-27495A

Trim Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-27904B

Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-29238B

4

Halyard Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-29662C

5

Lower Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . H-27374EF

Lacing Lines (3) 1/4" (6mm) Spectra®. . . . . . . . . . . . . HFG6907

Lower Unit

Assembly

May 2002 2/2.5 Carbon Furler 3

SPECIFICATIONS

■ ROD SIZES

-12, -17, -22 (7.14mm, 8.38mm, 9.53mm)

■ CLEVIS PIN SIZES

5

/8", 3/4" (15.9 mm, 19.1 mm)

■ LUFF TAPE SIZE

6

/32", (5mm)

#6,

■ RIGGING, ATTACHMENT TO LOWER UNIT

If no turnbuckle is required, attach the rod marine eye directly
to the integral toggle on the 2.5.

If a turnbuckle is required, it must terminate in a marine eye
that will fit directly to the integral toggle. Use a Navtec C560

5

turnbuckle or similar for rod with either a

3

/4" (19mm) pin diameter.

or

/8" (15.9mm) pin

■ TOOLS REQUIRED

Sharp Hacksaw, Sandpaper, Small Triangular File, Heat Gun,
Razor Knives, Sandpaper.

■ SUPPLIES REQUIRED FOR GLUING FOILS

Rigging tape, blue masking tape, 9430 Hysol Epoxy
(supplied), Scissors, mixing cup, mixing stick, glue brushes,
acetone, paper towels cut into quarters, plastic to cover
splint area, clear packaging tape, wood alignment stick
and placemat-sized table covering.

Alignment Splints - Use 90° angle extrusion to make splints.

3

Sides to be about

/4" (19mm). Cut extrusion into 8" (203mm)

lengths and remove burrs from cutting.

■ RETROFITS, FITTING ROD

If you plan to reuse the existing rod and turnbuckle:
Lower End—If you are using a standard Navtec turnbuckle

with integral toggle, the lower body must be replaced with a
standard Navtec marine eye body. Check to make sure that
this eye will mate with the Harken integral toggle. Two cross
pin sizes are available. They are the same size as the clevis
pin. See above.

Upper End—You must take apart the marine eye so that you
are left with a threaded nosepiece. Check to see if this is pos

­sible. If necessary, contact Navtec or Riggarna for correct pro
cedure. You will slip carbon foils over this threaded nosepiece.
If you cannot remove this fitting you will need to cut the rod.

■ HEADSTAY LENGTH

Note: When cutting rod to length or making up new rod, make
sure that you can take apart the rod terminal (usually the top
eye) so that you are left with a threaded nosepiece.

Make up the rod headstay or adjust the turnbuckle so the
Harken toggle fits below the rod terminal eye. The pin-to-pin

1

distance of the Harken toggle is 3

/4" (83mm).

Note: The 2.5 Carbon furler has an integral toggle. No
additional toggle is required below the furler.

-

4 2/2.5 Carbon Furler May 2002

PREPARATION FOR ASSEMBLY Foil Cut Length • Top Foil Cut Length • Short Top Foil? • Cutting Top Foil

■ FOIL CUT LENGTH

The Carbon 2.5 furler has an integral toggle. No additional toggle is required below the unit.
To check the foil length, lay foils alongside the stay before cutting top foil. Make sure

that turnbuckle is set to desired length.

A

■ TOP FOIL CUT LENGTH

Instructions for worksheet below:
1 Fill in total pin-to-pin headstay length.
2 Fill in A length.
3 Adjust B length if necessary.

Note: There must be enough space between top of carbon foils and bottom of rod
terminal to allow for turnbuckle adjustment. As turnbuckle is adjusted, terminal is
pulled down towards top of rod. If no turnbuckle is used, there only needs to be

1

minimal space—

/2" (12mm)–between the carbon foil and rod terminal.

We have put 4" (100mm) as a starting point. This may need to be adjusted based
upon how turnbuckle was set when headstay was measured. If there is less than
4" (100mm) “take-up”, less space can be left and vice versa. The space between foil
trim cap and bottom of turnbuckle must be more than “take-up” on turnbuckle.

4 Add A, B, E and subtract from total pin-to-pin headstay length. SUM = _________
5 Choose the number from foil multiplier below closest to, but not greater than,

sum from step 4. Fill in D length.

6 X 72" = 432 6 X 1828.8mm = 10972.8
7 x 72" = 504 7 x 1828.8mm = 12801.6
8 x 72" = 576 8 x 1828.8mm = 14630.4
9 x 72" = 648 9 x 1828.8mm = 16459.2
10 x 72" = 720 10 x 1828.8mm = 18288.0
11 x 72" = 792 11 x 1828.8mm = 20116.8

C

D

5 Add A, B, D, E. Subtract from pin-to-pin length for C (top foil length).

WORKSHEET: DETERMINE TOP FOIL LENGTH

Dimensions Inches mm

A Center of PIN to bottom of terminal _______ _______

E

B Bottom of terminal to top of foil 4 102

C Top foil _______ _______

Foils below 8" (203mm) see next page

D _____ x 72" (1828.8mm) foils _______ _______

E Top of feeder to center of clevis pin 523/4 1340

Total pin-to-pin headstay length

_______ _______

IF YOU HAVE SHORT TOP FOIL

If top foil is less than 8" (203mm) do not use a recessed top connector. The top foil must
be at least 4" (101mm). If it is less, shorten the upper 72" (1.83m) foil to make the upper
foil 4" (101mm).

CUTTING TOP FOIL

Once you have checked the top foil length by laying foils alongside the rod, use a sharp
hacksaw to cut top foil. Tape foil and cut along tape. Sand bottom end of the foil so it
is square and to remove any carbon burrs. Lightly sand inside of foil where it will be
bonded with 220 grit to remove any grease or mold release agent.

June 2002 2/2.5 Carbon Furler 5

PREPARATION FOR ASSEMBLY

Tape outside ends of all foils using blue masking tape. To
make sure tape edge lines up with end of foil, extend the
tape over foil end. Use a sharp razor knife to trim tape even
with foil.

Coat rod with mold release agent or wax to keep epoxy
from adhering.

Heat rod terminal and remove threaded screw and threaded
nosepiece. If rod terminal has been upset (peened), follow
Navtec or Riggarna procedures for removing peening.

Tape threads of nosepiece and tape nosepiece so it will not
slip down foil when pushing it back out.

6 2/2.5 Carbon Furler December 2001

ASSEMBLY

Assuming that installation is done from the top, slide
bottom foil onto rod so end with holes is at bottom
end of foil.

Slide feeder over so, so rounded sail groove corners will be at
the bottom end of foil.

Slide full-length 72" (1.83m) foils onto the rod.

Assemble connectors onto rod in preparation for glueing.
Place one bushing half in socket on either side of connector,
grooved side up. Bring connector up on rod and place other
bushing half on rod and rotate bushing so seam is at top
and bushing assembly stays in place.

Place foil on bench with grooves facing up and supported on
wood blocks.

June 2002 2/2.5 Carbon Furler 7

ASSEMBLY

You must follow four-step

mixing instructions shown

below exactly or the foil

connector bond will fail.

Adhesive Alert

Cool Weather

Temperature should be higher than 60°F (15°C).

If you glue at a lower temperature:

50°F (10°C) minimum

gently warm joints with a hair dryer to no more than:

100°F (38°C), a temperature at which you can still

hold the foil comfortably in your hand.

If glued in temperature less than 60°F (15°C, allow glued
foils to cure undisturbed for 48-hours before moving.

Warm Weather

Surfaces must be dry.

Remove plastic clip from Hysol® adhesive pack.

1) Mix for five minutes in bag.

2) Pour entire contents into cup.

3) Squeegee remaining epoxy into cup.

4) Continue to thoroughly stir epoxy in cup.

Adhesive Working Times:

75°F (24°C) - 1 hour

85°F (29°C) - 45 minutes

Allow glued foils to cure undisturbed for 24-hours

Use glue brush to coat the inside of the foil for one or two
inches. Coat 1/2 of the outside of the connector with epoxy
and slowly insert the connector into the foil. Work the con
nector in and out as you insert it to adhere the epoxy without
dry spots on the inside of the foil. As excess epoxy comes off
the connector, clean it up using the acid brush. Use excess
to coat feeder area of connector. Clean up the end of the foil
using paper towel wetted with acetone taking care that no
epoxy is in the sail grooves.

8 2/2.5 Carbon Furler May 2002

-

ASSEMBLY

Lightly coat feeder area of connector and slip feeder into
place.

Use glue brush to coat inside of foil for one or two inches.
Coat half the outside of connector with epoxy and slowly
insert connector into foil. Work connector in and out
as you insert to adhere epoxy without dry spots on inside
of foil. As excess epoxy comes off connector, clean up
using acid brush.

Clean up end of foil using paper towel wetted with acetone,
taking care that no epoxy is in sail grooves.

Coat the remaining half of connector with epoxy and insert
into foil as described above, cleaning up excess epoxy. Take
special care to clean epoxy from sail grooves.

May 2002 2/2.5 Carbon Furler 9

ASSEMBLY

Lay plastic against foil and place splint against foil. Tightly
wrap clear packaging tape around splint near both ends.
Insert wood alignment stick between foil and feeder and
inspect to make sure that foil/feeder are aligned.

Coat bottom foil reinforcement (torque tube connector) with
epoxy and insert into foil as directed above.

Insert plastic bushings in top connector as directed above.
Coat outside of connector with epoxy as directed above and
insert into top foil. Clean up excess epoxy.

Slide halyard swivel onto foils. Make sure swivel side is

towards top of stay!

Slide trim cap over threaded nosepiece. Heat cap in hot
water to help it slide over nosepiece. Attach trim cap using

®

Superglue

.
Make sure foils are straight and grooves are facing up.
Inspect lower unit to make sure that feeder and bottom foil

are aligned correctly. Allow to cure undisturbed overnight.

After curing overnight, remove splint. Use a small triangular
file to clean excess epoxy while tape remains in place.

Remove tape and use a razor knife to carefully remove any
excess epoxy. Make sure halyard swivel passes all points.

Install top rod eye using red Loctite® on locking screw or
with upset as per manufacturer's instructions.

Remove eight socket-head cap-screws located on underside
of lower unit and remove lower cap. Remove three set
screws located at top of torque tube.

10 2/2.5 Carbon Furler December 2001

ASSEMBLY

Slide lower unit onto bottom foil.

Assemble turnbuckle. Attach turnbuckle eye to toggle using
cross pin with tapered ends. Secure Cross Pin using Circlip
(Smalley Rings) supplied. Note: Make sure the end of the
toggle with the long slot is towards the bottom.

Bring the lower unit down so that Cross Pin seats in the

®

housing. Install cap using Blue Threadlocker

on the

eight screws.

■ FOIL HEIGHT

Check the clearance between the top of the foil and top
terminal.

TIP: Check clearance when the unit is on the ground,
before raising the headstay into position.

WARNING: It is critical to have clearance between the top
foil and the top rigging fitting when the stay adjuster is in
the fully closed position. If the fittings touch, the unit will
jam or in the case of a Sta-Lok fitting, the terminal may
become unscrewed. This could cause catastrophic
failure to the spar and a life threatening situation

It is the responsibility of the rigger to check clearance.

Long Slot

December 2001 2/2.5 Carbon Furler 11

COMMISSIONING Tying Soft Attachment Lines

You must lace line around the furler/halyard swivel three times
when attaching the sail or halyard.

Harken recommends us of a Hunter's Bend. This knot can
be highly tensioned without slipping and like a bowline can
be untied afterwards. There are other bends and knots that
will also work.

Lace line three times around the torque tube/halyard swivel
to capture sail or halyard. After lacing line, tie ends on side
opposite sail.

1 Form a loop in line that comes from left tunnel. Below this,
form a second loop with line from the right tunnel.

2 Twist loop clockwise and arrange ends of line so they are
below standing loops as shown.

12 2/2.5 Carbon Furler December 2001

COMMISSIONING Tying Soft Attachment Lines

3 Take end that is now
running down to right.
Tuck it down under
crossing lines
and up through
loop, towards
you.

4 Pass other end up and over crossing lines and then down
into loop, away from you.

5 At this point knot will not look anything like the finished
bend. Set knot by gently pulling on bitter ends and then
standing parts until it looks like Drawing 6.

December 2001 2/2.5 Carbon Furler 13

COMMISSIONING Tying Soft Attachment Lines

6

7 Finished bend drawn up and set. If your bend does not

look like this untie and repeat the process.

9 If furler is installed under deck, lace tack pendant as
pictured. Rigging a pendant directly from carbon tunnels
will damage unit.

8 It is important to keep tack/luff as close to torque tube and
as low as possible. A tack line that is too long will angle up
too far and damage the carbon tunnels. When sail is bent on,
check to make sure tack line is not pulling up against the
carbon tunnels.

14 2/2.5 Carbon Furler December 2001

COMMISSIONING Halyard Wraps • Prevent Halyard Wraps

■ HALYARD WRAPS

The most serious problem with furling systems occurs when
the jib halyard wraps around the headstay foil. Halyard wraps
will prevent furling or unfurling and may cause serious dam

­age to the unit and the halyard. In severe cases, halyard wraps
may cause loss of the headstay.

To prevent wraps, the halyard must exert a slight pull to
the rear. This allows the foils to turn while the halyard
remains stationary.

■ PREVENT HALYARD WRAPS

WARNING: The sail must be fitted to foils before operation.
1 Halyard swivel should be within top 4" (100mm) of foil.
2 Halyard must pull slightly to rear (8 - 10°).
3 Halyard must be snug, but not too tight.
If a halyard wraps, do not force unit to turn. Attempt to open

8 - 10°

sail by alternately furling and unfurling sail slightly.
If the sail can be unfurled, lower sail by releasing jib halyard.

Severe halyard wraps can only be cleared by going aloft and
freeing halyard.

If the sail will not furl or unfurl, it may be possible to remove
jib sheets and manually wrap/unwrap the sail around/from
the headstay.

Important: Testing at the dock does not indicate halyard angle
is correct. In wave action, halyard may wrap if lead angle is
not correct. The diverging 8-10° angle mentioned above is
critical.

December 2001 2/2.5 Carbon Furler 15

COMMISSIONING Pendants • Halyard Restrainer

■ PENDANTS

If your sail is not long enough to position halyard swivel
properly, you must add a pendant to sail. Pendants should
be plastic-coated wire permanently attached to the head of
sail so height will be correct. Adjustable length pendants
are not acceptable as they might not be adjusted correctly
during a sail change.

■ INSTALL A PENDANT
1 Raise sail, but do not attach tack shackle.

2 Position halyard swivel correctly near top of headstay
and secure halyard.
3 Secure a piece of rope to sail tack. Lead line through
tack shackle on furling drum and tension sail.
4 Measure distance from tack shackle to sail tack and
have a pendant of this length permanently attached to
head of sail.
5 Repeat this procedure for every jib.

TIP: Pendants are used at head of sail. Short pendants
may be added at tack to improve visibility under genoa, but
remember that visibility is already improved by shackling
to tack swivel. Tack pendants increase heeling moment
by raising sailplan. You may install pendants at both
head and tack of sail.

■ HALYARD RESTRAINER

To prevent wraps, the jib halyard must pull slightly to the
rear. On some boats the halyard sheaves are located too
close to the headstay and a halyard restrainer must be used.

Use halyard restrainers only when required by the masthead
geometry. Restrainers tend to limit sail luff length and may
cause problems if not properly installed.

Mount the restrainer as high as possible on the face of the
mast. Position the restrainer so the foils will not hit it when
under load.

The restrainer should deflect the halyard 8 - 10°. If the
angle is more than 10°, you may experience difficulty in

tensioning the sail luff, friction in furling and possible damage
to the foils. To decrease deflection angles, shorten the luff of
the sail.

TIP: Boats used in charter service should consider using a
halyard restrainer, regardless of masthead geometry.

8 - 10°

16 2/2.5 Carbon Furler December 2001

COMMISSIONING Halyard Tension

■ HALYARD TENSION

The jib halyard should be firm, but not too tight.

TIP: The luff foil system supports the sail along its entire
length so halyard tension is required only to shape sails,
not to support them. Use only enough halyard tension to
remove some wrinkles along the luff. Do not tension the
halyard enough to cause vertical wrinkles in the luff. Use
halyard tension to adjust draft position of the sail to suit
sailing conditions. Your halyard should be firm but not
tight. If in doubt, release halyard tension. To protect
the sail, ease the halyard when the boat is not in use.

December 2001 2/2.5 Carbon Furler 17

Corporate Headquarters

1251 East Wisconsin Avenue, Pewaukee, Wisconsin 53072 USA

Telephone: [phone]

Web: www.harken.com

• Fax: [phone] • Cable: Harken Pewaukee

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ZA. Port des Minimes, BP 3064, 17032 - La Rochelle Cedex 1, France

Telephone: [phone]

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• Fax: [phone]

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Via Marco Biagi, 14, 22070 Limido Comasco, (CO), Italy

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• Fax: [phone]

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Harken UK Ltd.

Bearing House, Ampress Lane

Lymington, Hampshire S041 8LW, England

Telephone: [phone]

• Fax: [phone]

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Email: [e-mail]

Harken Poland

ul. Lisa Kuli 4 Lok.1, 01-512 Warszawa, Polska

Telephone: [phone]

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[e-mail]

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S-440 30 Marstrand, Sweden

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Obala 107

6320 Portoroz, Slovenia

Telephone

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/Fax: [phone]

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Harken Australia, Pty, Ltd.

1B Green Street

Brookvale, N.S.W. 2100, Australia

Telephone: [phone]

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• Fax: [phone]

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30-36 Fanshawe Street

Auckland 1001, New Zealand

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• Fax: [phone]

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Please visit: http://www.harken.com/dealers/dealers.php

for an up-to-date list of Harken dealers and distributors

4362/9-08