Harken 7411.11 User Manual
MKIV UNDERDECK JIB REEFING & FURLING
Unit 1, 2, 3
Installation Manual – Intended for specialized personnel or expert users
Preassembly
Parts 4–5
Rigging Parts Check/Tools 6
Dimensions/Sailmaker's Instructions 7
Stay Length Deductions/Stay Into Foil Options 8
Hub Assembly
Deck Flange 9
Install Hub Assembly in Bow 10–11
Assemble Drum Components 11
Underdeck Lead Block 12
Preassembly
Top Foil Length (Unit 1) 13
Top Foil Length (Unit 2) 14
Top Foil Length (Unit 3) 15
Short Top Foil (Unit 1) 16
Short Top Foil (Unit 2) 17
Short Top Foil (Unit 3) 18
Confirm Foil Length 19
Assembly
Foils/Connectors 20–26
Halyard Swivel 26
Torque Tube Assembly 27
Rod Rigging 28
Attach Turnbuckle/Foils to Boat 29–31
Feeder/Final 32
Commissioning
Turnbuckle 33–34
Lead Line to Cockpit 35
Halyard Swivel Height/Angle 36
Halyard Restrainer/Tension 37
Operation
Halyard/Headstay Tension 38
Raise Sails/Storm Sails/Reefing 39–40
Secure Sail 40
Race Conversion 41
Maintenance
Clean/Lubricate/Inspect 42
Confirm Deck Flange/Tack Swivel Gap 42
Replace Line 42
Storage/Transporting 42
Remove Furler 42
Troubleshooting/Warranty
4656 01/14
Please read these instructions carefully before installing, servicing, or operating the equipment.
This manual may be modified without notice. See: www.harken.com/manuals for updated versions.
PLEASE SAVE THESE INSTRUCTIONS
Parts Description
Introduction
This manual gives technical information on installation and service. This information is destined exclusively for
specialized personnel or expert users. Installation, disassembling, and reassembling by personnel who are not
experts may cause serious damage to property or injury to users and those in the vicinity of the product. If you
do not understand an instruction contact Harken.
The user must have appropriate training in order to use this product.
Harken accepts no responsibility for damage or harm caused by not observing the safety requirements and
instructions in this manual. See limited warranty, general warnings, and instructions in www.harken.com/manuals.
Purpose
®
Harken
Jib Reefing and Furling is designed for rolling sails on sailboats to reduce sail size or to completely roll
so wind has little effect on the sail. Use of this product for other than normal sailboat applications is not covered
by the limited warranty.
Safety Precautions
WARNING! This symbol alerts you to potential hazards that may kill or hurt you and others
if you don't follow instructions. The message will tell you how to reduce the
chance of injury.
18
CAUTION! This symbol alerts you to potential hazards that may hurt you and others if
you do not follow instructions. The message will tell you how to reduce the
chance of injury.
WARNING! Strictly follow all instructions to avoid potential
hazards that may kill or hurt you and others. See www.harken.com/
manuals, for general warnings and instructions.
14
6
7
5
4
2
1
3
Parts Descriptions
1) Lower Jaw/Jaw Toggle
2) Threaded Stud
3) Length Adjuster Nut
4) Hub Assembly
2 MKIV Underdeck Unit 1, 2, 3
11
9
8
5) Flange Assembly
6) Guard Assembly
7) Cover Assembly
8) Deck Flange
13
12
WARNING! Do not drill boat's chainplate or toggle.
This may result in rig failure. Use the correct
size toggle and clevis pin.
10
2. Harken does not recommend drilling boat’s chainplate or toggle.
Bushings may be available to fit boats with smaller clevis pin sizes.
Part No. Size Wire Size Rod Size Clevis Pin Ø
7411.11
7412.11 5/
7413.11
7413.11
1
/
2
Unit 1
8
Unit 2
3
/
4
Unit 3
7
/
8
Unit 3
1
/4", 9/32", 5/16"
6 mm, 7 mm, 8 mm
5
/16", 3/8"
8 mm, 10 mm
7
/16", 1/2"
11 mm, 12 mm
7
/16", 1/2"
11 mm, 12 mm
15
Size Check
1. Check headstay and clevis pin
dimensions in chart below.
-8, -10
5.72 mm 6.35 mm
-12, -17
14 mm, 8.38 mm
-22, -30
9.53 mm, 11.1 mm
-22, -30
9.53 mm, 11.1 mm
9) Tack Swivel
10) Tack Shackle
11) Bearing Caps
12) Upper Jaw/Jaw Toggle
12.7 mm
15.9 mm
19.1 mm
22.2 mm
5
3
7
½"
/8"
/4"
/8"
16
Standard
Headstay Length
45' 11"
13.99 m
60' 4"
18.38 m
75' 1"
22.88 m
75' 1"
22.88 m
13) Torque Tube Universal
14) Torque Tube Assembly
15) Foil Clamp
16) Bottom Foil
19
17
Max.
Headstay Length
52' 11"
16.12 m
67' 4"
20.51 m
82' 1"
25.02 m
82' 1"
25.02 m
Preassembly Sizing Check
25
19
20
21
22
23
A B
24
26
E
D
F
C
Will Drum Fit in Bow?
H
Note: If length of stud does not allow attachment to chainplate, link plates
G
between chainplate and toggle must be fabricated.
Furler Requires Drained Compartment
Harken’s Underdeck Furler is designed to keep much of the water from
I
entering the bow compartment. Water will drip through the furler during
rain or when sailing in heavy weather. Furling compartment must drain.
Unit Part No. A B C D Max E F G Min G Max H Min H Max I J
1
2
3
3
7411.11
7412.11
7413.11
7413.11
1
/
2
51/2"
140 mm
5
/
8
65/8"
167 mm
3
/
4
83/16"
208 mm
7
/
8
83/16"
208 mm
49/16"
116 mm
51/16"
129 mm
61/2"
166 mm
61/2"
166 mm
411/16"
119 mm
51/4"
134 mm
3
6
/4"
172 mm
63/4"
172 mm
11/2"
38 mm
113/16"
46 mm
21/2"
64 mm
21/2"
64 mm
11
/
16
3
94 mm
3
/
16
"
4
106.5 mm
7
/
16
"
5
138.5 mm
7
/
16
"
5
138.5 mm
5
2
"
/16"
58 mm
3
2
/4"
70 mm
5
3
/8"
92 mm
5
3
/8"
92 mm
45/8"
117 mm
53/8"
137 mm
67/8"
175 mm
75/16"
186 mm
95/8"
244 mm
115/16"
287 mm
143/8"
365 mm
15"
381 mm
105/8"
270 mm
1211/16"
322 mm
161/8"
410 mm
169/16"
421 mm
J
155/8"
397 mm
189/16"
471 mm
5
23
/8"
600 mm
241/4"
616 mm
1
/2"
12.7 mm
5
/8"
15.9 mm
3
/4"
19.1 mm
7
/8"
22.2 m
41/8"
105 mm
5"
127 mm
65/16"
160 mm
65/16"
160 mm
17) Feeder
18) Connector Bushing
19) Bottom Connector
MKIV Underdeck Unit 1, 2, 3 3
20) 7' (2.13 m) Foil
21) Connector Screws
22) Connector Wedge
23) Connector
24) Halyard Swivel
25) Trim Cap Screws
26) Trim Cap
Preassembly Parts
Halyard Swivel
Cover Assembly
Flange Assembly
7' (2.13 m)
Foils
2' (610 mm)
Bottom Foil
Guard Assembly
Torque Tube
Assembly
Hub Assembly
Main Components
Part No.
Description Unit 1 Unit 2 Unit 3-3/4 Unit 3-7/8 Qty
Halyard swivel H-39812 H-39794 H-39392 H-39392 1
Torque Tube Assembly HFG927 HFG928 HFG929 HFG929 1
Hub Assembly HFG923 HFG924 HFG925 HFG926 1
Cover Assembly HFG683 HFG686 HFG689 HFG689 Pair
Flange Assembly HFG684 HFG687 HFG690 HFG690 Pair
Guard Assembly HFG685 HFG688 HFG691 HFG691 Pair
4 MKIV Underdeck Unit 1, 2, 3
Line (Not included with Furler)
Note: Line is not included with furler. Drum of
unit is smaller to allow it to fit into narrow bow
sections. If overlapping sails are used, standard
diameter line will fill up drum and jam furler. To
prevent this, use small diameter, high strength
line at forward end and have a rigger add a
cover at aft end where line is handled.
Line Specifications
Unit Forward Ø
1
1
/4" (6 mm) 2500 lb (1130 kg)
5
2
/16" (8 mm) 3740 lb (1700 kg)
3
3
/8" (10 mm) 5000 lb (2270 kg)
Foils (Standard Package)
Description Unit Part No. Qty
7' (2.13 m) Foil
2' (610 mm) Bottom foil 7411.33 1
7' (2.13 m) Foil
2' (610 mm) Bottom foil 7412.33 1
7' (2.13 m) Foil
2' (610 mm) Bottom foil 7413.33 1
Min Break
Strength Aft Ø
5
/16" (8 mm)
3
/8" (10 mm)
7
/16" (12 mm)
7411.30 6
1
7412.30 8
2
7413.30 10
3
Preassembly Parts
Connector Bushings
Trim Cap Screws
Bottom
Connectors
Connector
Hex Keys (Supplied)
Description Unit Qty
2.5, 4, 5 mm 1 1 Each
3, 4, 5, 6 mm 2 1 Each
3, 4, 6, 10 mm 3 1 Each
Other Components
Unit 1 Unit 2 Unit 3 (3/4, 7/8)
Description Part No. Qty Size Part No. Qty Size Part No. Qty Size
Connector
Bottom connector
Bow shackle
7411.31 5 7" (177.8 mm) 7412.31 7
7411.32 1 10.75" (273 mm) 7412.32 1
2110 3 6 mm 2117 3
Plastic
Connector
Wedges
Prefeeder
Bow Shackles
Hex Keys
Blue Loctite
Foil Screws
®
Red Loctite
9" (229 mm)
13" (330 mm)
8 mm
Feeder
®
7413.31
7413.32
2124
Trim Cap
Injector
Adhesive
9 9.75"(248 mm)
1 14" (356 mm)
3 10 mm
5200
Unit 1 Unit 2 Unit 3 (3/4, 7/8)
Description Part No. Qty Part No. Qty Part No. Qty
Connector bushing set
Plastic connector wedge set
Foil screw set
Trim cap set
Trim cap screw set
Prefeeder
Feeder with screw and tab
Injector, 1 oz. 5200 Adhesive
®
Loctite
Blue
®
Loctite
Red
MKIV Underdeck Unit 1, 2, 3 5
HFG295
(12-H-42062/12-H-42063)
HFG299
(14-H-39625)
HFG343
(28-HFS1105)
HFG680
(H-37361/H-37362)
HFG629
(3-HFS1126)
947
H-39683
HFG725
833
HFG739
1
1
1
1
1
1
1
1
1
2
HFG296
(16-H-42032/16-H-42033)
HFG300
(18-H-39487)
HFG348
(36-HFS1106)
HFG681
(H-37403/H-37404)
HFG672
(3-HFS1127)
947
H-39559
HFG725
833
HFG739
1
(20-H-42073/20-H-42074)
1
1
1
1
1
1
1
1
2
HFG297
HFG324
(22-H-39487)
HFG349
(44-HFS1106)
HFG682
(H-39751/H-39752)
HFG672
(3-HFS1127)
947
H-39756
HFG725
833
HFG739
1
1
1
1
1
1
1
1
1
2
Preassembly Rigging Parts Check/Tools
1. Stud/eye turnbuckle components are not included and
must be purchased separately. See page 8.
2. Rod rigging requires Harken rod adapter stud.
3. Order Harken Lead Blocks and one additional
7403 if necessary. Fits 1" (25 mm) stanchions.
Unit 1, 2
7404 Lead Block Kit
(Sold Separately)
131, 047
349, 2652
Recommended Furling
Compartment Lead Blocks
Unit Turning Thru-Deck
1 349 131
2 2652 047
3 2600/137/071 HC7981
Tools You Will Need
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
Rod Adapter Stud
Unit Part No. Thread Ø
7422 -8
1
7423 -10
7424 -12
2
7425 -17
7426 -22
3
7427 -30
1
/2" - 20RH
1
/2" - 20RH
5
/8" - 18RH
5
/8" - 18RH
3
/4" - 16RH
7
/8" - 14RH
Adhesive Alert
MKIV Furlers are shipped with 3M 5200
adhesive. Use adhesives on dry connectors
and foils using the special injection system
described in the assembly section. Parts
may immediately be exposed to rain. Cure
is best at 70F (22C) with 50% humidity. Do
not apply at temperatures below 40F (5C)
and above 100F (38C).
Although adhesive has not cured it will
remain in place on foil joints whether
they are left on the ground or raised up
on boat. Foils can be raised immediately
after assembly and sails fitted.
Note: A small amount of adhesive may
bulge out of injection ports. If possible
let system sit for a couple days before
sailing. If adhesive gets on sails remove
using acetone. For faster-curing adhesive,
purchase 4200 Fast Cure.
Note: Damaged foils can be repaired.
Use a hand-held propane torch to heat
joints until foils can be pulled apart.
Unit
5
16
3
1
8
Unit Drill Ø
1
2
3 (3/4, 7/8)
4
12
5
5
1
/32"
/32"
/8"
(3 mm)
(4 mm)
(4 mm)
, 1/4"
, 1/4"
, 1/4"
(6.25 mm)
(6.25 mm)
(6.25 mm)
15
Unit
18
2
Deck
Flange Ø
1 3.7"
(94 mm)
2 4.2"
(106.5 mm)
3 5.45"
(138.5 mm)
Wrench Size
for Length Adjuster
1
2 1"
3 1.25"
7
(22 mm)
(25 mm)
(32 mm)
Saw Size
(95 mm)
(110 mm)
(140 mm)
/8"
19
6
10
13
Use 6 mm bolts and washers to
mount deck flange. To figure bolt
length, add 3/8" (10 mm) to deck
thickness. Minimum thread
7
9
11
14
1. Long tape measure 6. Side cutters 11. Center punch 16. Hole saw
2. Short tape measure 7. Rat-tail file 12. Rigging or black tape 17. Deck sealant
3. Power drill 8. Hex Keys (provided) 13. Scissors 18. Box end wrench
4. Drill bits (see chart) 9. Slotted/phillips screwdrivers 14. Metal straight edge 19. 6 mm bolts, nuts and washers
5. Hacksaw 10. Needle-nose pliers 15. Hammer
6 MKIV Underdeck Unit 1, 2, 3
17
engagement must be 9mm.
Hole
3 ¾"
4 ¼"
5 ½"
Preassembly Dimensions/Sailmaker's Instructions
Luff Length
Note offsets above and below sail.
A shorter luff may be required if a halyard restrainer is necessary
(page 37) or a toggle or long toggle assembly is used to raise drum.
If luff of sail is not long enough to put halyard swivel near top of
headstay foil, a pendant must be added. See page 36.
A
B
Tack Setback
Find setback "C" for tack shackle in chart below and modify sail
accordingly. Setback is measured to luff tape of sail.
Luff Tape Size
6
All units require #6 (
/32" or 5 mm) luff tape.
Luff Tape Length
Cut off top of luff tape so it is 18 to 24" (450 to 600 mm) below
head of sail. This allows head to lag behind rest of sail to help
flatten sail. It will also help head to roll more smoothly.
Note feeder height and extend bottom of luff tape downward so
it is below feeder. This will prevent luff tape from catching in
feeder as sail is lowered.
Tack and Head Shackles
F
Make sure tack and head shackles fit sail
rings. The minimum inside dimensions
of standard head and tack shackles are:
A
Unit A B
1
1
/16" (27 mm)1/2" (13 mm)
1
3
2
/4" (44 mm)
1
7
3
/8" (48 mm)
C
1
11
/16" (17 mm)
13
/16" (21 mm)
B
Suncover
Suncovers may be installed on either side of sail. Be
E
D
G
Unit Part No. A B C D E F G
1 7411.11 1/
2 7412.11
3 7413.11
3 7413.11
sure to match other sails in the customer's inventory.
43/4"
2
120 mm
55/8"
5
/
8
143 mm
75/16"
3
/
4
186 mm
75/16"
7
/
8
186 mm
7"
177 mm
91/8"
231 mm
115/8"
296 mm
115/8"
296 mm
115/16"
49 mm
25/16"
59 mm
33/16"
81 mm
33/16"
81 mm
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
—
9
/16"
14mm
7
/16"
11mm
—
13
/16"
37
960 mm
411/16"
1043 mm
473/16"
1199 mm
1
/16"
46
1170 mm
35/8"
92 mm
41/16"
104 mm
53/8"
136 mm
513/16"
148 mm
MKIV Underdeck Unit 1, 2, 3 7
Preassembly Deduction for Stay Length/Stay Into Foil Options
Use dimensions of Harken toggle below to build stay to correct length.
Tip: Turnbuckles should be 1/2 to 2/3rds open to allow shortening for new wire stretch and for fine-tuning mast rake.
A
B
C
D
Unit Part No. A B C D
1 7411.11
2 7412.11
3 7413.11
3 7413.11
1
/
2
5
/
8
3
/
4
7
/
8
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
5
3
/8"
92 mm
1
4
/8"
104 mm
53/8"
136 mm
513/16"
148 mm
105/8"
270 mm
1211/16"
322 mm
1
16
/8"
410 mm
169/16"
421 mm
155/8"
397 mm
189/16"
471 mm
235/8"
600 mm
241/4"
616 mm
Options for Snaking Stay into Foils
1. Swage stud at end of wire.
2. Open end of wire and install Norseman or Sta-Lok
®
stud after
foil is assembled.
3. Rod adapter nosepiece for Harken rod adapter stud: Threaded
nosepiece must have a positive lock as well as adhesive.
Use Harken stud with cotter pins. See page 28.
WARNING! Using a threaded nosepiece with only
adhesive at the upper rod eye terminal may result
in headstay system failure. Make sure there is a
mechanical lock.
8 MKIV Underdeck Unit 1, 2, 3
Assembly Deck Flange
1
/2°
–
74
1
/2°
72
Note: Deck flange angle
matches a stay angle of
1
/2° when compared
73
to deck. Angles can vary
1
between 72
/2° and 741/2°.
Carefully locate center point in deck to
locate deck flange. Line from mast to
under deck chainplate must intersect this
center point. Mark center fore/aft and
athwartships line. Use template to mark
four outer holes and center pilot hole.
Make sure closer pair of holes is forward.
Once you are certain hole is located in
line with chainplate and any required
shimming is done, drill hole 90° to deck.
Make sure hole is just large enough so deck
flange bears against deck. It is better to
make hole slightly smaller and file opening
larger to fit. Use template to mark large hole
and bolt holes. Use hole saw to drill deck.
Tip: After pilot drill bit clears deck, drill final
hole from bottom using pilot hole to line up
hole drilled from top. This will prevent glass
from chipping.
If deck does not fall within these angles,
shims must be made using structural
adhesive to avoid excessive pressure
on deck and deck bearings.
Use 6 mm screws and compound to fasten
deck flange.
3
Note: There must be a minimum of
/8"
(9 mm) thread engagement into deck flange.
MKIV Underdeck Unit 1, 2, 3 9
Assembly Install Hub Assembly in Bow
Slide hub assembly into deck
flange. Turn adjusting nut to
lengthen or shorten threaded
stud as needed.
Stud Length Turn Adjusting Nut
Shorten Clockwise
Lengthen Counter-Clockwise
Adjust length so toggle is lined up with chainplate hole. Slide pin
into chainplate and secure with cotter pin.
1
1
/16"–
/8"
2–4 mm
Distance between bottom of
tack swivel and deck flange
1
must be
/16"–1/8" (2–4 mm).
From on-deck, pull up on unit to check height between deck flange and
tack swivel. Make sure tack swivel is free to rotate when there is upward
pressure on unit. Check this again when stay is up and tensioned.
10 MKIV Underdeck Unit 1, 2, 3
Assembly Assemble Drum Components
Place halves of plastic flange in
lower groove on hub assembly
so smooth side of flange is up.
Tip: Line up flats in flange with
flats in groove.
Place halves of plastic cover in
grooves so flats in cover align
with flats in groove.
Tip: Rotate each screw hole
towards the stern.
Use blue Loctite
®
screws (provided).
Use blue Loctite
®
screws (provided).
on flathead
on flathead
Tighten screws using hex key
(provided).
Tighten screws using hex key
(provided).
Assemble line guard so enclosed
opening faces lead block. Do not
®
use Loctite
on threads.
Tip: Loosely thread both screws
turning guard so it can be rotated
to its final position. Finish
tightening final screw when
enclosed opening faces lead
block.
MKIV Underdeck Unit 1, 2, 3 11
Assembly Underdeck Lead Block
Mount lead block so that line exits furler
at 90° to line of headstay as shown.
Remember block will split angle and raise
up slightly under load. Mount thru-deck
block. You may want to angle it toward
stanchion block.
90°
Mount thru-deck block. You may want to
angle it toward stanchion lead block.
12 MKIV Underdeck Unit 1, 2, 3
UNIT 1
Preassembly Unit 1—Top Foil Length
Measure A and add to this chart
and length chart below
Inches mm
A
B .50 13
E 24 610
F 15.25 387
Total A+B+E+F
Make sure upper
measurement points
of A and pin-to-pin
Alternate
Measurement
Point
A
are the same.
TOP FOIL LENGTH WORKSHEET
1
2
3
4
To find “D” pick number from chart below that is closest to, but not greater than total from step 3.
5
Result (Pin-to-Pin – ABEF)
Inches mm
3 x 84 = 252
4 x 84 = 336
5 x 84 = 420
6 x 84 = 504
7 x 84 = 588
8 x 84 = 672
Example–If result from Step 3 is:
500 inches “D” = 420 inches 12,000 mm
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEF
Subtract D
3 x 2133.6 = 6400.8
4 x 2133.6 = 8534.4
5 x 2133.6 = 10668
6 x 2133.6 = 12801.6
7 x 2133.6 = 14935.2
8 x 2133.6 = 17068.8
“D” = 10,668 mm
–
–
Pin
to
Pin
A
B
C
D
Pin
to
Pin
Length Check
After completing worksheet above fill in A, C and D below. Add “A”
through “F” to confirm total equals your pin-to-pin measurement.
A Center of Pin to Bottom of Terminal
B Bottom of Terminal to Top of Foil
C Top Foil Length
D Number of Foils ________ x 84" (2133.6 mm)
E Bottom Foil 24 610
F Bottom of Foil to Jaw/Jaw Toggle 15.25 387
Length Chart
Dimensions Inches mm
.50
Pin-to-Pin Length
13
E
F
MKIV Underdeck Unit 1 13
UNIT 2
Preassembly Unit 2—Top Foil Length
Measure A and add to this chart
and length chart below
Inches mm
A
B .63 16
E 24 610
F 18.45 469
Total A+B+E+F
Make sure upper
measurement points
of A and pin-to-pin
Alternate
Measurement
Point
A
are the same.
TOP FOIL LENGTH WORKSHEET
1
2
3
4
To find “D” pick number from chart below that is closest to, but not greater than total from step 3.
5
Result (Pin-to-Pin – ABEF)
Inches mm
5 x 84 = 420
6 x 84 = 504
7 x 84 = 588
8 x 84 = 672
9 x 84 = 756
Example–If result from Step 3 is:
500 inches “D” = 420 inches 12,000 mm
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEF
Subtract D
5 x 2133.6 = 10668
6 x 2133.6 = 12801.6
7 x 2133.6 = 14935.2
8 x 2133.6 = 17068.8
9 x 2133.6 = 19202.4
“D” = 10,668 mm
–
–
Pin
to
Pin
A
B
C
D
Pin
to
Pin
Length Check
After completing worksheet above fill in A, C and D below. Add “A”
through “F” to confirm total equals your pin-to-pin measurement.
A Center of Pin to Bottom of Terminal
B Bottom of Terminal to Top of Foil
C Top Foil Length
D Number of Foils ________ x 84" (2133.6 mm)
E Bottom Foil 24 610
F Bottom of Foil to Jaw/Jaw Toggle 18.45 469
Length Chart
Dimensions Inches mm
.63
Pin-to-Pin Length
16
E
F
14 MKIV Underdeck Unit 2
UNIT 3
(
3/4, 7/8
)
Preassembly Unit 3—Top Foil Length
Measure A and add to this chart
and length chart below
Inches mm
A
B 1 25
E 24 610
F 23.4 594
Total A+B+E+F
Make sure upper
measurement points
of A and pin-to-pin
are the same.
Alternate
Measurement
Point
A
TOP FOIL LENGTH WORKSHEET
1
2
3
4
To find “D” pick number from chart below that is closest to, but not greater than total from step 3.
5
Result (Pin-to-Pin – ABEF)
Inches mm
7 x 84 = 588
8 x 84 = 672
9 x 84 = 756
10 x 84 = 840
11 x 84 = 924
Example–If result from Step 3 is:
800 inches “D” = 756 inches 20,000 mm
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEF
Subtract D
7 x 2133.6 = 14935.2
8 x 2133.6 = 17068.8
9 x 2133.6 = 19202.4
10 x 2133.6 = 21336
11 x 2133.6 = 23470
“D” = 19,202 mm
–
–
Pin
to
Pin
A
B
C
D
Pin
to
Pin
Length Check
After completing worksheet above fill in A, C and D below. Add “A”
through “F” to confirm total equals your pin-to-pin measurement.
A Center of Pin to Bottom of Terminal
B Bottom of Terminal to Top of Foil
C Top Foil Length
D Number of Foils ________ x 84" (2133.6 mm)
E Bottom Foil 24 610
F Unit 3-
F Unit 3-
3
/4–Bottom of Foil to Jaw/Jaw Toggle 24 610
7
/8–Bottom of Foil to Jaw/Jaw Toggle 23.4 594
Length Chart
Dimensions Inches mm
1
Pin-to-Pin Length
25
E
F
MKIV Underdeck Unit 3 15
Preassembly Unit 1—Short Top Foil
UNIT 1
If top foil is shorter than 7" (177.8 mm), use one of the following special techniques to ensure sufficient bearing
surface for the foil in the area of the halyard swivel.
" (38 mm)
/2 (64 mm)
7" (178 mm)
/2
1
1
2" (51 mm)
2
1" (25 mm)
1
Cut-Offs
Do Not Use
7" (178 mm) No special treatment required.
21/2"–1" (64–25 mm) Shorten top foil and adjoining
full length foil so two screws are used to assemble joint
instead of four. Do not use plastic bushings above top
connector.
6"–5" (150–130 mm)
Cut-Offs
Do Not Use
6"–5" (152–130 mm) Do not use plastic bushing above
top connector.
/2"–4" (115–100 mm)
1
4
41/2"–4" (115–102 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if
necessary shorten trim cap.
Cut-Offs
Do Not Use
Top Foil
Length from
Worksheet
1
2
/2"
(64 mm)
2"
(51 mm)
1
/2"
1
38 mm)
1"
(25 mm)
1. Initial
top foil
cut length
57/8"
(149 mm)
5
(137 mm)
47/8"
(124 mm)
4
(111 mm)
3
/8"
3
/8"
2. Cut through
middle hole in
top foil.*
Resulting Top
Foil Length Length
41/8"
(105 mm)
35/8"
(92 mm)
31/8"
(79 mm)
25/8"
(67 mm)
3. Shorten
full length
adjoining
foil by
cutting
through
middle
hole.*
4. Shorten
connector
(89 mm)
(89 mm)
(89 mm)
(83 mm)
5. Shorten
trim cap
31/2"
31/2"
31/2"
31/4"
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
No
No
Yes
Yes
/2" - 3" (90 - 75 mm)
1
3
Cut-Offs – Do Not Use
31/2"–3" (90–75 mm) Do not use plastic bushing above
top connector. Cut connector right at cross formed by
glue dispersion channels. Use single foil screw in top
foil only.
16 MKIV Underdeck Unit 1
Under 1" (25 mm)
Under 1" (25 mm) Eliminate top foil and run foil higher
in torque tube.
Preassembly Unit 2—Short Top Foil
UNIT 2
If top foil is shorter than 8
11
/16" (221 mm), use one of the following special techniques to ensure sufficient
bearing surface for the foil in the area of the halyard swivel.
/16" (221 mm)
11
8
811/16" (221 mm) No special treatment required.
/8" (219–162 mm)
3
/8"–6
5
8
Cut-Offs
Do Not Use
85/8" – 63/8" (219–162 mm) Do not use plastic bushing
above top connector.
2" (64 mm)
2" (38 mm)
/
1
3" (76 mm)
/
1
2" (51 mm)
2
1" (25 mm)
1
Cut-Offs
Do Not Use
3"–1" (76–25 mm) Shorten top foil and adjoining full
length foil so two screws are used to assemble joint
instead of four. Do not use plastic bushings above top
connector.
Top Foil
Length from
Worksheet
3"
(76 mm)
1
/2"
2
(64 mm)
2"
(51 mm)
1
/2"
1
(38 mm)
1"
(25 mm)
1. Initial
top foil
cut length
7
(184 mm)
63/4"
(172 mm)
6
(159 mm)
53/4"
(146 mm)
5
(133 mm)
1
/4"
1
/4"
1
/4"
2. Cut through
middle hole in
top foil.*
Resulting Top
Foil Length Length
51/8"
(130 mm)
45/8"
(117 mm)
41/8"
(105 mm)
35/8"
(92 mm)
31/8"
(79 mm)
3. Shorten
full length
adjoining
foil by
cutting
through
middle
hole.*
4. Shorten
connector
(114 mm)
(114 mm)
(114 mm)
(95 mm)
(95 mm)
41/2"
41/2"
41/2"
33/4"
33/4"
5. Shorten
trim cap
No
No
No
Yes
Yes
/2" (152–140 mm)
1
6"–5
Cut-Offs
Do Not Use
Cut-Off
Do Not Use
6"–51/2" (152–140 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if
necessary shorten trim cap.
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
/8" (133–92 mm)
5
Cut-Offs – Do Not Use
/4"–3
1
5
Under 1" (25 mm)
51/4"–35/8" (133–92 mm) Do not use plastic bushing
above top connector. Cut connector right at cross formed
by glue dispersion channels. Use single foil screw in top
foil only.
MKIV Underdeck Unit 2 17
Under 1" (25 mm) Eliminate top foil and run foil higher
in torque tube.
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