Harken 1782 User Manual

1816 Track: 6’915/16" (2.08 m) long track.

Number of sections will vary according
to luff length.

Make sure you have the correct size
track. System C track is 11/4" (32 mm)
wide.

Track for Drilling and Tapping
516/758/1847 Track: You must use

516/758/1847 track for drilling and
tapping. Use

5

/

16

" (8 mm) FH screws,
not included.
Do not use 1816 open backed track for
drilling and tapping the mast. This track
must have the support of the mounting
slugs.

See page 8 for mounting instructions.

2

Sizing

Make sure that you have the
correct size Battcar system
for your boat.

Maximum Sail Area

System

Monohull Multihull

Maximum

Boat Length

1400 ft

2

130 m

2

1200 ft

2

111 m

2

80’

24 m

C

Parts List

BATTCARS

Flat Battslide®fitting with
threaded post is shown. You
may have toggle attachment,
round batten ends or SDA
batten fittings (not included).

LUFF CARS

Luff cars not required

if battens are close

enough to support sail.

Plastic spacers go

to sailmaker

MOUNTING KIT

One required for each track.

END KIT

One required for each system.

HEADBOARD ASSEMBLY

2 - Headboard Cars

1 - Coupler

7 - 19 mm Rings

19 - Mounting Slugs

1” (25 mm)

1 - Connector Slug

4

1

/8" (105 mm)

2 - Tubes

Blue Loctite

®

21 - Flathead Screws

8 mm x 25 mm (1")

2 - End Stop Slugs

2" (51 mm)

4 - Flat Head Screws

8 mm x 40 mm (1

9

/16")

2 - End Stops

1 - Tube

Blue Loctite

®

3

/4”

(19 mm)

11/4” (32 mm)

11/4

” (32 mm)

2 - Headboard Plates

2 - Tubes Blue Loctite

®

1 - Batten Receptacle

1 - Battcar

6 - Screws

6 - Barrel Nuts

Sail Spacers

3

Required Tools Determining Track Length

Phillips screwdriver Drill
Tape measure

21

/64" (8.5 mm) drill bit
Putty knife File
Hacksaw Tape
Hammer Socket wrench
Center punch Power driven screwdriver
Step Ladder: If you are installing the system with

the mast up, use a step ladder that can be secured
to the boat near the mast.

You will need to work at a hand height of
about 7' (2.13 m) above the gooseneck.

Note: Track length is

greater than

luff length of sail.

The track must extend at least 9" (229 mm) above the point where the halyard is
attached to the Harken headboard. Allow for sail stretch.

Make sure the top of the track does not interfere with the halyard exiting from the
mast.

The set back for the halyard from the aft side of the mast is 41/2" (114 mm). See
Diagram A.

Remember to leave 3/8" (10 mm) beyond each end of the track for the end stops.
At the lower end, the track must extend as close to the gooseneck as possible

and ideally below the top of the boom.

Adjusting 1816 Track Length

The length of the track is matched to the mast by adjusting the number of 6'915/16

"

(2.08 m) track lengths and by cutting the top and bottom track pieces to length.
Consult chart below to determine how many total track pieces you will need.
Consult the charts below to determine whether you need to cut your top track to

length.
All mast lengths will require cutting the bottom track. A short bottom track allows

cars to be easily loaded. See page 9.

How 1816 Many Track Sections?

Use the chart below to determine the total number of full length 6'915/

16" (2.08 m)

track sections required for installation.
The variable length top and bottom tracks are included in this number.

Track Length of Mast

(As Described in Diagram A)

Number of 6'915/

16

" (2.08 m)

Track Sections Required

56'3" to 61'6"

(17.145 m to 18.745 m)

9

61'7" to 68'4"

(18.771 m to 20.828 m)

10

68'5" to 75'2"

(20.853 m to 22.911 m)

11

75'3" to 82'

(22.936 m to 24.994 m)

12

82'1" to 88'10"

(25.019 m to 27.076 m)

13

95'9" to 97'2"

(29.185 m to 29.616 m)

88'11" to 95'8"

(27.102 m to 29.159 m)

15

14

Full Length 6'91/8" (2.06 m) Top Track

Round your track length to the nearest 1" (25 mm). If your track length is one of the dimensions shown below, your track system does not
need a special length top track. A full length 6'915/16" (2.08 m) track is used as the top track.

56'3" (17.145 m) 63'1" (19.228 m) 69'11" (21.311 m) 76' 9" (23.393 m) 83' 7" (25.476 m) 90'5" (27.559 m)
56'4" (17.170 m) 63'2" (19.253 m) 70' (21.336 m) 76'10" (23.419 m) 83' 8" (25.502 m) 90'6" (27.584 m)
56'5" (17.196 m) 63'3" (19.279 m) 70' 1" (21.361 m) 76'11" (23.444 m) 83' 9" (25.527 m) 90'7" (27.610 m)
56'6" (17.221 m) 63'4" (19.304 m) 70' 2" (21.387 m) 77' (23.470 m) 83'10" (25.552 m) 90'8" (27.635 m)
56'7" (17.247 m) 63'5" (19.329 m) 70' 3" (21.412 m) 77' 1" (23.495 m) 83'11" (25.578 m) 90'9" (27.661 m)

DIAGRAM A: Determining Track Length

41/2"

(114 mm)

Total Track Length (as defined on page 4)

Top Track Length

7" (178 mm)

57' (17.374 m) 63'10"(19.456 m) 70' 8"(21.539 m) 77' 6"(23.622 m) 84' 4"(25.705 m) 91' 2"(27.788 m) 9" (229 mm)

57' 2"(17.424 m) 64' (19.507 m) 70'10"(21.590 m) 77' 8"(23.673 m) 84' 6"(25.756 m) 91' 4"(27.838 m) 11" (279 mm)

57' 4"(17.475 m) 64' 2"(19.558 m) 71' (21.641 m) 77'10"(23.724 m) 84' 8"(25.806 m) 91' 6"(27.889 m) 13" (330 mm)

57' 6"(17.526 m) 64' 4"(19.609 m) 71' 2"(21.692 m) 78' (23.774 m) 84'10"(25.857 m) 91' 8"(27.940 m) 15" (381 mm)

57' 8"(17.577 m) 64' 6"(19.660 m) 71' 4"(21.742 m) 78' 2"(23.825 m) 85' (25.908 m) 91'10"(27.991 m) 17" (432 mm)

57'10"(17.628 m) 64' 8"(19.710 m) 71' 6"(21.793 m) 78' 4"(23.876 m) 85' 2"(25.959 m) 92' (28.042 m) 19" (483 mm)

58' (17.678 m) 64'10"(19.761 m) 71' 8"(21.844 m) 78' 6"(23.927 m) 85' 4"(26.010 m) 92' 2"(28.092 m) 21" (533 mm)

58' 2"(17.729 m) 65' (19.812 m) 71'10"(21.895 m) 78' 8"(23.978 m) 85' 6"(26.060 m) 92' 4"(28.143 m) 23" (584 mm)

58' 4"(17.780 m) 65' 2"(19.863 m) 72' (21.946 m) 78'10"(24.028 m) 85' 8"(26.111 m) 92' 6"(28.194 m) 25" (635 mm)

58' 6"(17.831 m) 65' 4"(19.914 m) 72' 2"(22.996 m) 79' (24.079 m) 85'10"(26.162 m) 92' 8"(28.245 m) 27" (686 mm)

59' 2"(18.034 m) 66' (20.117 m) 72'10"(22.200 m) 79' 8"(24.282 m) 86' 6"(26.365 m) 93' 4"(28.448 m)

59' (17.983 m) 65'10"(20.066 m) 72' 8"(22.149 m) 79' 6"(24.232 m) 86' 4"(26.314 m) 93' 2"(28.397 m)

58'10"(17.932 m) 65' 8"(20.015 m) 72' 6"(22.098 m) 79' 4"(24.181 m) 86' 2"(26.264 m) 93' (28.346 m)

58' 8"(17.882 m) 65' 6"(19.964 m) 72' 4"(22.047 m) 79' 2"(24.130 m) 86' (26.213 m) 92'10"(28.296 m)

35" (889 mm)

33" (838 mm)

31" (787 mm)

29" (737 mm)

59' 6"(18.136 m) 66' 4"(20.218 m) 73' 2"(22.301 m) 80' (24.384 m) 86'10"(26.467 m) 93' 8"(28.550 m)

59' 4"(18.085 m) 66' 2"(20.168 m) 73' (22.250 m) 79'10"(24.333 m) 86' 8"(26.416 m) 93' 6"(28.499 m)

59' 8"(18.186 m) 66' 6"(20.269 m) 73' 4"(22.352 m) 80' 2"(24.435 m) 87' (26.518 m) 93'10"(28.600 m)

37" (940 mm)

41" (1.041 m)

59'10"(18.237 m) 66' 8"(20.320 m) 73' 6"(22.403 m) 80' 4"(24.486 m) 87' 2"(26.568 m) 94' (28.651 m) 43" (1.092 m)

60" (18.288 m) 66'10"(20.371 m) 73' 8"(22.454 m) 80' 6"(24.536 m) 87' 4"(26.619 m) 94' 2"(28.702 m) 45" (1.143 m)

60' 2"(18.339 m) 67' (20.422 m) 73'10"(22.504 m) 80' 8"(24.587 m) 87' 6"(26.670 m) 94' 4"(28.753 m) 47" (1.194 m)

60' 4"(18.390 m) 67' 2"(20.472 m) 74' (22.555 m) 80'10"(24.638 m) 87' 8"(26.721 m) 94' 6"(28.804 m) 49" (1.245 m)

60' 6"(18.440 m) 67' 4"(20.523m) 74' 2"(22.606 m) 81' (24.689 m) 87'10"(26.772 m) 94' 8"(28.854 m) 51" (1.295 m)

60' 8"(18.491 m) 67' 6"(20.574 m) 74' 4"(22.657 m) 81' 2"(24.740 m) 88' (26.822 m) 94'10"(28.905 m) 53" (1.346 m)

60'10"(18.542 m) 67' 8"(20.625 m) 74' 6"(22.708 m) 81' 4"(24.790 m) 88' 2"(26.873 m) 95' (28.956 m) 55" (1.397 m)

61' (18.593 m) 67'10"(20.676 m) 74' 8"(22.758 m) 81' 6"(24.841 m) 88' 4"(26.924 m) 95' 2"(29.007 m) 57" (1.448 m)

61' 2"(18.644 m) 68' (20.726 m) 74'10"(22.809 m) 81' 8"(24.892 m) 88' 6"(26.975 m) 95' 4"(29.058 m) 59" (1.499 m)

61' 4"(18.694 m) 68' 2"(20.777 m) 75' (22.860 m) 81'10"(24.943 m) 88' 8"(27.026 m) 95' 6"(29.108 m) 61" (1.549 m)

61' 6"(18.745 m) 68' 4"(20.828 m) 75' 2"(22.911 m) 82' ((24.994m) 88'10"(27.076 m) 95' 8"(29.159 m) 63" (1.600 m)

61' 8"(18.796 m) 68' 6"(20.879 m) 75' 4"(22.962 m) 82' 2"(25.044 m) 89' (27.127 m) 95'10"(29.210 m) 65" (1.651 m)

61'10"(18.847 m) 68' 8"(20.930 m) 75' 6"(23.012 m) 82' 4"(25.095 m) 89' 2"(27.178 m) 96' (29.261 m) 67" (1.702 m)

62' (18.898 m) 68'10"(20.980 m) 75' 8"(23.063 m) 82' 6"(25.146 m) 89' 4"(27.229 m) 96' 2"(29.312 m) 69" (1.753 m)

62' 2"(18.948 m) 69' (21.031m) 75'10"(23.114 m) 82' 8"(25.197 m) 89' 6"(27.280 m) 96' 4"(29.362 m) 71" (1.803 m)

62' 4"(18.999 m) 69' 2"(21.082 m) 76' (23.165 m) 82'10"(25.248 m) 89' 8"(27.330 m) 96' 6"(29.413 m) 73" (1.854 m)

62' 6"(19.050 m) 69' 4"(21.133m) 76' 2"(23.216 m) 83' (25.298 m) 89'10"(27.381 m) 96' 8"(29.464 m) 75" (1.905 m)

62' 8"(19.101 m) 69' 6"(21.184 m) 76' 4"(23.266 m) 83' 2"(25.349 m) 90' (27.432 m) 96'10"(29.515 m) 77" (1.956 m)

79" (2.007 m)

63' (19.202 m) 69'10"(21.285 m) 76' 8"(23.368 m) 83' 6"(25.451 m) 90' 4"(27.534 m) 97' 2"(29.616 m) 81" (2.057 m)

Cutting Top Track To Length

62'10"(19.152 m) 69' 8"(21.234 m) 76' 6"(23.317 m) 83' 4"(25.400 m) 90' 2"(27.483 m) 97' (29.566 m)

56' 8"(17.272 m) 63' 6"(19.355 m) 70' 4"(21.438 m) 77' 2"(23.520 m) 84' (25.603 m) 90'10"(27.686 m)

56'10"(17.323 m) 63' 8"(19.406 m) 70' 6"(21.488 m) 77' 4"(23.571 m) 84' 2"(25.654 m) 91' (27.737 m)

39" (990 mm)

5" (127 mm)

4

5

Cutting Top Track To Length

Use a file to deburr the cut.
Slightly round off the corners of the track

that will slide against the mast so it will not
catch when sliding the track up the mast.

If your track length is shown in the chart
on page 4, use a hacksaw to cut a special
length of top track from a 6'915/

16" (2.08 m)

track.
Round your track length to the nearest

1

/2"
(10 mm) and extrapolate to determine the
top track length.

Drill two 21/64" (8.5 mm) holes in the cut end
of the top track centered at 9/16" (14 mm) and
15/

8" (41 mm) from the track end.

Slip the rubber end stop over the cut end
of the top track.

Before You Start...will mounting slugs and cars fit?

NOTE: You will cut the bottom track in Step 10.

Clear of Trysail Track?

To make sure the track will tighten against
mast, put a mounting slug in the groove, a
track section on the mast and use a screw
to test.

Also, make sure mounting screw is long
enough for your mast groove.

Check to make sure the 41/8" (105 mm) long
connector slug will fit in the feeder opening.
If necessary, use a file to make the feeder
opening longer.

Use a halyard to run the 41/8" (105 mm) long
connector slug up the entire mast. Use a
retrieval line. If it jams, clean the groove.

If there is prebend in the mast, you may
need to straighten it out somewhat to
install the battcar system.

Warning! Screws must have three (3) or

more threads engaged to hold track to mast.
Make sure screw makes three (3) full 360°

rotations after threads engage in slug.

Cars are 23/4" (70 mm) wide. Make sure they
do not hit trysail track or other obstruction
up the entire spar. Note: tracks often
converge above the spreaders.

Check Fit

Will Tighten

Will Not Tighten

35/16" (84 mm)

6

1

Slip the slugs for the

top track into the mast
groove starting with 2"
(51 mm) end stop slug.

Make sure the 41/

8"

(105 mm) connector
slug is at the bottom.

If the mast is up, tape the
2" (51 mm) slug in place
so it will be even with
the top of the upper track.

Tape the other slugs
in place.

Installing Track

2

Put a drop of blue

Loctite into each
connector slug hole.

3

Thread a 19/16"

(40 mm) long end
stop screw through the
rubber end stop, track
and into end stop slug.

If the mast is up, remove
the tape and tighten the
screw enough to hold
the track in place.

Loosely install the other
1

9

/

16

" (40 mm) screw.

4

Use a putty knife to

slide the next slugs
into place and loosely
install the 1" (25 mm)
screws.

5

Loosen the top screw

and slide the top track
up far enough to place
the next 6'915/16" (2.08 m)
track in place.

Mast up: tighten bottom
screw to hold the track
in place.

6

Slide 19 mounting

slugs and a connector
slug into the mast groove.

Mast up: tape in place.
Put a drop of blue

Loctite®in each hole.

Tip: Use the putty knife
as a feeler gauge to
make sure the screws
are loose enough to
slide easily in the
groove.

REMEMBER: The tracks
may slide up the lower
part of the mast but
may hang up when they
reach a spliced area of
the mast.

7

Installing Track

Hold a full-length track
piece up to the mast and
loosely install the top
screw.

Warning! Do not let
tracks drop, severe
injury can result if the
upper track(s) drop
down.

Use a putty knife to slide
the next slugs and
connector slug in place
and loosely install the
1" (25 mm) screws.

7

Slide tracks up far
enough to fit the

next track.
Mast up: hold upper

tracks, loosen screw that
holds the tracks in place
and slide track up.
Loosen screw enough so
the track will slide up the
mast.

Securely tighten the
new bottom screw.

8

Repeat until all full
length tracks are

installed.
Do not install the 41/8"

(105 mm) connector
slugs at this time.

Note: If the bottom full
length track blocks the
feeder gap, load slugs for
the bottom track

before

installing the full length
track.

Slip slugs below the gap.
Begin with 2" (51 mm)
end stop slug, followed
by the mounting slugs,
and the 41/8" (105 mm)
connector slug on top.

9

Push tracks up so the

187/8

" (479 mm) to

22

7

/8" (581 mm) bottom
track will fit below. See
step 10. The rubber end
stop extends 3/8" (10 mm)
below the bottom of the
track.

Do not install the bottom
track yet.

10

Refer to the chart
below to find your

bottom track length.
From the track that is

remaining, measure from
the anodized end and cut
the track.

11

Drill a 21/

64"

(8.5 mm) end stop

hole

9

/16" (14 mm) from
the cut end of the bottom
track.

The other hole will be
in the track unless your
track length is shown in
the chart above. If so,
drill the second hole
15/8" (41 mm) from the
end of the track.

12

Check the fit of the
bottom track, but

do not install it. See
step 13–15.

Securely tighten those
screws that you can reach
from your mounting posi­tion. Go to the top of the
mast and come down,
securely tightening all
screws.

Round your track length to the nearest 1" (25 mm).

Make the bottom track 187/8" (479 mm) if not listed below.

56'7"

(17.247 mm)

63'5"

(19.329 mm)

70'3"

(21.412 mm)

77'1"

(23.495 mm)

83'11"

(25.578 mm)

90'9"

(27.661 mm)

If your track length is listed below, make the bottom track 227/8" (581 mm)

56'6"

(17.221 mm)

63'4"

(19.304 mm)

70'2"

(21.387 mm)

77'0"

(23.470 mm)

83'10"

(25.552 mm)

90'8"

(27.635 mm)

If your track length is listed below, make the bottom track 217/8" (556 mm)

56'5"

(17.196 mm)

63'3"

(19.279 mm)

70'1"

(21.361 mm)

76'11"

(23.444 mm)

83'9"

(25.527 mm)

90'7"

(27.610 mm)

If your track length is listed below, make the bottom track 197/8" (505 mm)

If your track length is listed below, make the bottom track 207/8" (530 mm)

56'4"

(17.170 mm)

63'2"

(19.253 mm)

70'

(21.336 mm)

76'10"

(23.419 mm)

83'8"

(25.502 mm)

90'6"

(27.584 mm)

8

Installing Track by Drilling and Tapping

Start at one end of track and work down: drilling, tapping and screwing. Do not drill and tap
both track ends and then expect to drill and tap the center holes.

Clamp or duct tape track in place on mast. Center punch hole being careful to locate center
of track hole.

Drill through track hole, making sure drill is perpendi­cular to face of mast. Take care to not let the chuck hit
the track. Tap threads and install screws using blue
Loctite®.

Aligning track at joints: The 1786 splice pieces will help
align the track as you are installing the track. In addi­tion, use round rods or dowels to align tracks. Use
spring clamps or “C” clamps to hold them in place
until the track is drilled, tapped and screwed in place.

Follow instructions on page 9 regarding loading cars
and installing bottom track.

Tip: For accuracy and ease of punching use a spring loaded machinist's center punch. Use
the narrow shaft model with a centering tube fashioned from a piece of plastic tubing.

Required Parts

Before You Remove Old Track

Before taking old track off, scribe a pencil line down either side of
track to use as a guide for keeping track straight. If the track is off
the mast, use a string attached to the mast to help line up the track
while installing.

Drilling and Tapping

548

1786

516/758/1847 Track

See page 3, Determining Track Length. The bottom track length
needs to be short enough to remove easily to put cars on or
take them off the track. We recommend an 18” to 24" (457 mm
to 609 mm) bottom track length.

Do not use 1816 track for

drilling and tapping.

5

/16" (8 mm) Flathead Screws (not included)

Number of fasteners needed:

516 Track — 3 fasteners/foot of track
758/1847 Track — 10 fasteners/meter of track

1786 Splice Pieces
548 End Stop Set

516/758

1 9

Loading Cars On Track

13

Slide cars onto the

track beginning
with the two headboard
cars (1782 headboard
cars have lug in the
center).

Slide Battcars onto the
track. 1784/1795: make
sure that the housing
for the vertical shaft is
at the top of the car.

If the mast is up, use a
halyard to hold the cars.

Tip: Hold car loader
against the track firmly
until the car is com­pletely on the upper
tracks.

14

Slip the connector

slug into the mast
groove and install this on
the bottom full length
track piece.

Slip the remaining three
or four mounting slugs
and end stop slug in
place and tape them
if necessary.

15

Install bottom track

and lower end stop
using blue Loctite on
screws. Securely tighten
all screws.

Mast

Track

End stop

Screws

Note: End stop screws
must go through track
or stop is not effective.

16

Ease cars onto
bottom section.

17

Install the head-

board coupler so
that the cotter pin end of
the clevis pin is toward
the middle of the coupler.

10

Loading Sail On Car

Diagram B:
1784/1795 cars.

3

1784 or 1795 cars:

tighten the locknut
until you begin to feel
shaft of Battslide®bind
when you rotate it in car.

Loosen the locknut 1/8th
turn from this point.

Tightening the locknut
too tightly or failing
to use a washer will
damage the plastic
liner.

5

Attach headboard of
sail to the headboard

coupler.
Raise sail and check to

make sure that sail is
not too tall.

If necessary, have sail
shortened.

1

Load the sail beginning with the lower cars. Luff cars: remove
clevis pin, slip plastic center sleeve between tangs. Slip clevis in

place. Secure with a cotter pin. Make sure webbing is not twisted.

4

1828/1829/1903 cars:

slip batten receptacle
tang into toggle forks.
Secure with clevis pin
and cotter pin.

2

1784 or 1795 cars:

slip plastic bushing
into each end of car lug.
Insert shaft of Battslide

®

fitting into barrel so
threaded end points
up. You must use

3

/8" (10 mm) washer
between plastic shaft
bushing and nut.
See Diagram B.

11

Lazy Jacks

Operating Precautions

Maintenance

Removing Sail

HARKEN

HARKEN

Use shock cord to hold lazy jacks open
so that the battcars and battens will not
catch on them. This will also help stop
slapping of lazy jacks on sail.

Attach one end to the lower spreader tips
and the other to the lazy jacks.

Make sure the shock cord is long enough
so the boom can swing out all the way
without damaging the spreaders.

When lowering sail, do not simply let the halyard go. Ease cars down by keeping a wrap on the winch.
On boats with unstayed masts, vang must be used to prevent over rotation of upper part of sail. Over rotation

can damage batten receptacles.

Clean the cars at the beginning of the season or if the cars
begin to bind. Squirt detergent and water into the ball bearings
and move the cars up and down to circulate the detergent. Let
the detergent sit a few minutes and then spray water into the
balls and circulate to remove detergent. Do not use spray
lubricants on cars or tracks.

Clean tracks by washing with detergent and water. After the
track is dry you may apply a dry spray lubricant like McLube

®

.

Inspect Battcar fittings for signs of locknuts loosening or
plastic bushings wearing. If

3

/8"-16 locknuts are not holding,
replace them. Inspect batten receptacles for signs of screws
loosening.

Inspect plastic bushings in Battcars for wear. Replace bushings
if necessary.

If it is necessary to remove the cars for any reason, use a car
loader. See step 13.

1784/1795

Taking care not to lose the stainless steel washer and plastic bushings, remove nut and slide the vertical post out of the Battcar.
See page 10. Note: replace 3/8" nut after two uses.

DIAGRAM C

12

Sailmaker’s Instructions

Part

No.

Description

Max

Batten

Width or

Diameter

Max

Thickness

Batten

w/Cloth

Batten
Shape

A B C D E

1784

1782

Battcar w/aluminum
Mega Battslide

®

Headboard car
assembly w/headboard

31/8"

79 mm

—

5

/8"

16 mm

—

Flat

—

43/4"

121 mm

113/16"

284 mm

25/16"

59 mm

21/16"

53 mm

33/16"

81 mm

45/8"

117 mm

513/16"

148 mm

10"

254 mm

3

/8 -16

1

/2"

12 mm

1828

1785

Battcar w/pivoting
adjustable Battslide

®

(round batten)

Luff car

3

/

4

"

19 mm

—

——Round

—

43/

4"

121 mm

4"

102 mm

25/

16"

59 mm

25/16

"

59 mm

33/

16"

81 mm

211/16

"

68 mm

91/

2"

241 mm

11/8

"

29 mm

5

/

16"

8 mm

5

/16

"

8 mm

1827

1795

Battcar w/12 mm
stud for SDA fitting

Battcar w/adjustable
Battslide®(round batten)

1"

25 mm

3

/4"

19 mm

——Round

Round

43/4"

121 mm

43/4"

121 mm

25/16"

59 mm

25/16"

59 mm

211/16"

68 mm

33/16"

81 mm

—

83/4"

222 mm

5

/16"

8 mm

3

/8-16

1829

Battcar w/pivoting
Mega Battslide

®

31/8"

79 mm

5

/8"

16 mm

Flat

43/4"

121 mm

25/16"

59 mm

33/16"

81 mm

63/8"

162 mm

5

/16"

8 mm

1903

Battcar w/pivoting
adjustable Battslide

®

(large round battens)

1"

25 mm

— Round

43/4"

121 mm

25/16"

59 mm

33/16"

81 mm

12"

305 mm

3

/8"

16 mm

Installing 1782 Headboard Plates

Make sure that height of sail is correct
and setbacks are uniform. Refer to the
chart above for the correct setbacks
and alignment of the headboard.

Install headboard with narrow corner
facing upwards.

Use 3/16" aluminum semi-tubular rivets in
the 20 smaller holes.

Place the liner in the headboard so it is equally
spaced above and below the headboard.

Use a closing tool for the 19 mm stainless
liners supplied with the headboard.

Closing Tools:

Rutgerson 19 mm closing tool.
C423 Howe & Bainbridge for

7

/8" ring

(used with #23 ring).
C410 Howe & Bainbridge for

7

/

8" ring

(used with 210 Innox ring).

Distance Between Attachment Points

Battens and luff cars should be placed according to sailmaker's discretion. Usual distance between attachment points is 4' to 4'6"
(1.2 m to 1.35 m).

The distance may be greater if luff is stiffer. If attachment distance is greater, pretension the boltrope so that there is no flapping between
attachment points.

Setting Up Reef Points

Space reef points so that they are halfway between sail attachment
points. Especially with upper reef where sail needs to extend past the
stack of cars to the reef tack fitting. Battens or reef points may need
to be moved to allow this.

NOTE: The batten fittings cannot handle reefing outhaul or down­haul loads. Make sure these loads are transferred to a tack fitting
such as a reefing hook.

Attaching Sail to Luff Cars

The sail setback from the luff tape to the bearing point of the luff car
is 7/

8" (22 mm).

Plastic hourglass-shaped spacers are shipped on the luff cars.
Seize the spacer to the webbing by stitching just behind the plastic

spacer. This will make it easier to slip the pin into the strap and will
reduce wear on the strap. See diagram F.

Also seize the webbing to the sail by stitching up against the sail.

DIAGRAM E

DIAGRAM F

DIAGRAM D

7/8" (22 mm)

13

Use a cloth to fill in the space between the ears of the
headboard plates.

Use enough pressure so rings will fit in coupler. The inside dimen­sion of the coupler is 11/16" (18 mm).

Make sure the ring fits inside the coupler.

Sailmaker’s Instructions

14

Assembling Harken 1784 Battcar and 1829 Mega Battslide

®

1784 and 1829 fits battens with widths up to 31/8" (80 mm).
Battens wider than 21/2" (64 mm) require tapering.

Note: Remove sharp edges from the forward end of battens with a file or sanding block.

DIAGRAM G

1

With batten installed loosely in pocket, place Battslide®batten
receptacle over boltrope, centered on batten pocket tape.

Make sure receptacle is snug against boltrope and that bolt

rope is straight.

2

Mark the mounting screw holes. Punch them with a 1/4"
or 9/32" (7 mm) punch.

3

Choose a combination of plastic sail grippers that suit the thick-

ness of the sail. Put at least one gripper on each side of the sail.
Grippers should fit as snugly as possible with no space between
them and the cheeks of the batten receptacle.

4

Install a barrel nut and 10-24 screw through one of the forward
holes; align the sail grippers and tighten the first screw to main-

tain position of entire assembly. Use blue Loctite®on barrel nuts.

5

If there is slack between the side of batten and receptacle cheek,
fill it with appropriate thickness of green laminated batten

material.

6

Install the remaining barrel nuts, sail grippers and screws.
Tighten firmly. Note: when using tubular battens,

do not

overtighten

to the point of cracking the batten.

7

The fifth (center) hole is an optional bolt hole for flat battens.
This is recommended.

Sailmaker’s Instructions

15

Assembling Harken 1795, 1828 and 1903 Battcars with Adjustable Round Batten Battslides

®

Sailmaker’s Instructions

DIAGRAM H

1

Determine which side of sail to mount battens.The batten recepta-

cle may be installed on the port or starboard side of the sail.
The receptacle is shipped for starboard side installation. For port-

side, reverse the batten compression assembly and install the
link holder on the opposite end of the batten receptacle.

Port or starboard batten location is a matter of preference, but
may be influenced, for example, by the location of a storm
trysail track along one side of the mast.

2

Align the Battslide®fitting with the batten pocket and with the

bolt rope. Make sure the round batten chamber is above the
hexagonal chamber.

Mark and punch six holes for the 8-32 mounting screws and one
larger hole at the forward end for the inch diameter clevis pin.

1794 Battslides

®

are intended primarily for use on sails with
horizontally-oriented battens; however, if the upper battens are
slightly inclined, the Battslides

®

will accommodate this.

3

Use six 8-32 screws and locknuts to sandwich the sail between
the backing plate and the batten receptacle.

The screw heads must be on the backing plate side, and the nuts
on the receptacle side, as shown in the illustration.

4

To fit the battens, loosen the batten adjustment screw and
remove the batten compression traveler.

Round the aft end of the batten, insert it through the forward end of
the receptacle and push it as far aft into the leech end of the batten
pocket as possible.

With a pencil, mark the batten at the forward end of the receptacle.
Pull the batten out of the receptacle a slight distance and cut it off
about 1" (25 mm) aft of the pencil mark to allow room for the batten
compression traveler and the link holder.

Note: If the diameter of the batten is less than 3/4" (19 mm),
use enclosed 3" long cylinders to sleeve the batten.

Glue sleeves to the forward end of the battens.
Sleeves are available from Harken in limited sizes or they can

be fabricated from plastic tubing.

5

Reinstall the batten compression traveler and

5/16"-18 locknut.
Tighten the traveler about 1/4" (6 mm) after it contacts the batten.
Align the 1/4" (6 mm) holes in the receptacle, backing plate and link

holder. Install the clevis pin with the head on the receptacle side
and secure it with the cotter ring.

6

The batten compression can be adjusted using a 1/2" socket

wrench with a 3" (76 mm) extension. Some adjustment will
be required after the first sail.

Harken 1795, 1828 and 1903 Battcars fit round battens up to

3

/4" (19 mm) diameter. Sleeves are included for battens below 3/4" (19 mm).

16

Installation Troubleshooting

Problem Probable Cause Solution

Cut end of top or bottom track is at joint

Make sure the anodized end is towards the
full length track

Tracks do not butt up against each other

Track weight pulling tracks apart

Tracks will come together when you loosen the bot­tom screw and push the tracks up the mast

Mounting slugs do not fit Slugs wrong size Different size slug required. Contact your dealer

Mounting screws will not tighten Incorrect mounting slug used Different size slug required. Contact your dealer

Slugs catching on mast splice

Loosen screws slightly. If necessary have someone at
splice area to wiggle the slug past the splice

Corners of cut track catching Use file to round off corners of track

Mast has too much prebend Ease backstay

Track will not slide up mast

Paint or other material clogging mast groove Clean out groove

Headboard coupler does not fit Cars are loaded on mast in the wrong order

Remove cars onto car loaders and load in the
correct order

Track and cars are not the same size Contact your dealer or Harken

Cars do not fit on track

Balls are missing

Remove cars onto car loaders, load balls and slide
cars back on track

Sail headboard does not fit inside coupler Ring was not pressed far enough Take sail to sailmaker

Operation Troubleshooting

Problem Probable Cause Solution

Batten receptacle upside down

Remove nut on batten receptacle post, install so
nut is at the top of the car

Car is on upside down

Remove cars onto car loader and install so barrel
is near the top of the car

Balls missing from car

Remove cars onto car loader, load balls and slide
cars back on track

Cars bind

Dirt in cars

Use detergent and fresh water to flush dirt out of
cars; move cars up/down to circulate; follow with
high pressure water, clean track grooves

Nut on Battcar is not holding Locknut has been used too many times Get new 5/

8" - 18 locknut

Batten receptacle does not rotate Nuts are too tight Loosen nuts slightly

Plastic bushings in Battcar are breaking Washer not used Install washer under nut for vertical post

Cars jam when raising sail Headboard or cars are catching on lazy jacks

Use topping lift or rod vang and shock cord to pull
lack jacks out to shrouds

Sail will not go all the way up Sail is too tall or sheave is too far forward Have sail shortened or move sheave aft

Reef tack fitting will not reach reef hook

Vertical post or pin on batten receptacle bending

Reef point too close to sail attachment

Reef loads are being transferred to batten receptacle

Have sailmaker move reef point or change reef
tack fitting

Transfer reef downhaul and outhaul loads to mast
or boom gooseneck

1251 E. Wisconsin Avenue, Pewaukee, WI 53072
Tel : [phone] • Fax: [phone] • Website: harken.com • E-mail: [e-mail]

Printed in USA 4357/4-00

Corporate Headquarters

1251 East Wisconsin Avenue, Pewaukee, Wisconsin 53072 USA

Telephone: [phone]

Web: www.harken.com

• Fax: [phone] • Cable: Harken Pewaukee

• Online Catalog: www.harkenstore.com

Email: [e-mail]

Harken France

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

Telephone: [phone]

• Fax: [phone]

Web: www.harken.fr

Email: [e-mail]

Harken Italy S.P.A.

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

Telephone: [phone]

• Fax: [phone]

Web: www.harken.it

Email: [e-mail]

Harken UK Ltd.

Bearing House, Ampress Lane

Lymington, Hampshire S041 8LW, England

Telephone: [phone]

• Fax: [phone]

Web: www.harken.co.uk

Email: [e-mail]

Harken Poland

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

Telephone: [phone]

Web: www.harken.com

Email: [e-mail]

Harken Sweden

Mjölkekilsgatan 8, Box 64

S-440 30 Marstrand, Sweden

Telephone: [phone]

• Fax: [phone]

Web: www.harken.se

Email: [e-mail]

Harken Adriatik d.o.o.

Obala 107

6320 Portoroz, Slovenia

Telephone/Fax: [phone]

Web: www.harken.si

Email: [e-mail]

Harken Australia, Pty, Ltd.

1B Green Street

Brookvale, N.S.W. 2100, Australia

Telephone: [phone]

• Fax: [phone]

Web: www.harken.com.au
Email: info.harken.com.au

Harken New Zealand, Ltd.

30-36 Fanshawe Street

Auckland 1001, New Zealand

Telephone: [phone]

• Fax: [phone]

Web: www.harken.co.nz

Email: [e-mail]

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

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

Printed in USA 4357/9-09