Assembly manual for
Furlex
200 S, 300 S,
400 S & 500 S
with rod forestay
595-111-E
2004-12-15
RODSTAY
2
T 40
T 30 –
–
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.
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.
1.1 The manual
This manual covers assembly of the rod forestay and replaces the corresponding headings in the
”Manual Furlex 200 S & 300 S” (ref. no. 595-104-E). resp ”Manual Furlex 400 S & 500 S” (ref. no.
595-116-E).
These instructions is included in Furlex box. See ”Contents” on Page 3.
It is very important to read both manuals and note any cross references.
All safety-related information is indicated by the following symbol:
The manual covers four different Furlex sizes, 200 S, 300 S, 400 S and 500 S. The assembly proceedings varies on some points between the different sizes. This is marked in the manual.
The model designation can be found on the line drum top.
All dimensions specified in the manual are in millimetres (mm) unless otherwise indicated.
The screws used for the halyard swivel and lower bearing assembly have a Torx or Allen socket. The
requisite spanners are included with the Furlex. The table below gives the relevant screw sizes and
corresponding sockets.
Skrew Size Torx Socket Allen Socket
M 8
M 6
M 5
M10
M12
T 25
–
–
Fig: 1.1.a
–
8 mm
10 mm
Fig: 1.1.b
3
Pag e
1 Introduktion
1.1 The manual 2
1.2 Product information 4
1.3 Compatible sizes 6
MONTERING
2 Checklist
2.1 Furlex box 7
2.2 Foil pack 9
2.3 Joining sleeve pack 10
2.4 Tools 10
3 Assembly preparations
3.3.2 Dimensions of top eye terminal 11
3.5 Calculating the length of the
rod forestay 12
3.5.1 Calculation table 1:
Length of rod forestay 12
3.6 Calculating the length of
the luff extrusion 13
3.6.1 Calculation table 2:
Length of luff extrusion 13
4 Assembly of the Furlex-system
4.1 Assembly of the rod forestay 16
4.2 Assembly of the luff extrusion
200 S & 300 S 17
4.2 Assembly of the luff extrusion
400 S & 500 S 19
4.3 Fitting the line drum
and line guide 200 S & 300 S 24
400 S & 500 S 25
17 Dismantling
17.1 Halyard swivel 27
17.7 Luff extrusion system 27
17.8 Top guard 27
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 the function of its displacement, ballast, beam and
draught. 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 downwind and facilitating fast sail changes for racing yachtsmen.
The aluminium extrusion is insulated from the forestay over its whole length. Furlex 200 S, 300 S
and 400 S has the extrusion joining sleeves are also 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
1.3 Compatible sizes
1)
As the male part of this rod terminal type/size is too large to pass through the luff extrusions, the
rod forestay can only be cold-headed at its upper terminal end after the stay has been pulled through
the assembled extrusions. The extrusion must be made 200 mm (8”) shorter than the stay at the top
to make room for the cold-heading machine. Consequently the luff extrusions length and available
sail space is reduced. The system has to be manufactured by the rod manufacturer, which may give
rise to transportation problems.
2)
The upper eye terminal must be of the MNY type.
–
•
•
Limits imposed by strength
of furling system
Partial
rig
Furlex
8.0
Forstay
dim.
300 S
Navtec OYS
2
(Riggarna)
BSI
Rod diameter
Max. righting
moment at
30° heel (Nm)
Mast-
head
rig
Partial
rig
Mast-
head
rig
75.000
190.000
250.000
14
28
38
15
30
40
200 S
200 S
200 S
300 S
-8 (ø 5.7 mm)
-10 (ø 6.4 mm)
-12 (ø 7.1 mm)
-15 (ø 7.5 mm)
1
-12 (ø 7.1 mm)
-15 (ø 7.5 mm)
-17 (ø 8.4 mm)
-22 (ø 9.5 mm)
400 S
12 mm
10 mm
8 mm
8 mm
7 mm
6 mm
-30 (ø 11.1 mm)
-30 (ø 11.1 mm)
400 S
14 mm
-40 (ø 12.7 mm)
500 S
16 mm
-40 (ø 12.7 mm)
-48 (ø 14.3 mm)
37.000
70.000
180.000
230.000
40.000 7.5
Approximate
displacement
(tons)
•••
•••
•
–
•
•–•
–••
•–•
•••
•••
•––
•••
••–
•••
7
400 S/Ø12
Rigging screw adapter
Wire terminal (200 S & 300 S with spacer
bush) or Furlex rigging screw function.
(Depends on which type ordered.)
Halyard swivel with snap shackle/D-shackle
Lower bearing assembly with snap
shackle/D-shackle
2x line drum halves
(one with furling line end lock
200 S & 300 S)
Line guide fitting
2 Checklist
2.1 Furlex box
ASSEMBLY
8
500 S: Halyard leads are not included.
A halyard sheave box must be used for this
model. (
See ”Manual Furlex 400 S & 500 S”,
ref no. 595-116-E. Chap. 5.2, Fig: 5.2.a, page 24.)
300 S:
2 halyard leads 508-128 with
insulator sheets incl. 6 screws
Drill bit Ø 5.3 mm (7/32”)
Furling line
200 S:
2 halyard leads 508-159 with
insulator sheets incl. 4 screws
Drill bit Ø 5.3 mm (7/32”)
200 S & 300 S: Torx spanner set
400 S & 500 S:
Torx spanner set + Allen keys 8 (5/16”)
and 10 mm (3/8”).
200 S:
4 stanchion blocks 538-971-02
300 S:
4 stanchion blocks 538-210-01
+ 1 x 538-971-01
400 S & 500 S:
6 stanchion blocks 538-210-01
Locking adhesive
Lubricating grease
Line drum casing
Line guide locking block
400 S:
2 halyard leads 508-128 with
insulator sheets incl. 6 screws
Drill bit Ø 5.3 mm (7/32”)
9
200 S, 300 S and 400 S:
2400 mm (94 1/2”) luff extrusions with slotted distance tubes (number dependent
on length ordered.)
500 S: 4800 mm (189”) luff extrusions with
distance tube + joining sleeve (number
dependent on length ordered).
200 S, 300 S and 400 S: Sail feeder (sail
feeder + sailfeeder connector)
500 S: The sail feeder is cut into the
1000 mm luff extrusion on this model.
One 1000 mm (39 3/8”) luff extrusion
One 2000 mm (78 3/4”) luff extrusion
with slotted distance tube
2.2 Foil pack
Top guard incl. 2 screws
Instructions
Spare parts list
Certificate of guarantee
200 S, 300 S and 400 S:
1 short connecting plate for each
2400 mm (94 1/2”) luff extrusion
200 S, 300 S and 400 S:
1 long connecting plate (for sail feeder)
500 S: 1 short connecting plate for each
4 800 mm luff extrusion
200S & 300 S:
1 locking pin Ø 3 x 25 (Ø 1/8” x 1”) for
1000 mm (39 3/8”) luff extrusion
400 S & 500 S:
2 x bushes for 1000 mm (39 3/8”) luff extrusion
10
Tools needed for assembly:
Screwdriver
Hacksaw
2 adjustable spanners
“Polygrip” pliers
Adhesive tape
File
Marker pen (water-proof)
Torx spanners (included in Furlex package)
Steel measuring tape (30 m) (100”)
Knife
200 S, 300 S och 400 S:
For halyard leads:
Heavy-duty Philips screwdriver
Drill
Drill bit Ø 5.3 mm (7/32”)
(included in Furlex package)
2.4 Tools
1 long joining sleeve with insulator
(not 500 S)
Short joining sleeves with insulators
(not 500 S)
(number dependent on length ordered)
Socket
1 seat for rod forestay in lower bearing
assembly
500 S: Socket and seat forms one part
Instructions
2.3 Joining sleeve pack
The joining sleeve pack and foil pack may be delivered as a combined
package.
400 S & 500 S:
Bearing plug
-8 (ø 5.7 mm)
11
3 Assembly preparations
3.1 Forestay attachment –
guiding principle
3.2 Mast attachment
3.3 Deck attachment
3.3.1 Dimensions of lower
bearing assembly
See “Manual Furlex 200 S & 300 S”
(ref. no. 595-104-E)
resp. ”Manual Furlex 400 S & 500 S”
(ref. no. 595-116-E).
Fig: 3.3.2.a
3.3.2 Dimensions of top eye terminal
3.3.3 Toggle dimensions
3.4 Assembly below deck
TEL
TED
1)
Type MYE cannot be used.
}
}
TET
See ”Manual Furlex 200 S & 300 S”
(ref. no. 595-104-E) resp.
”Manual Furlex 400 S & 500 S”
(ref. no. 595-116-E).
OYS
(Riggarna)
––––––
Rod diameter
BSI
TET TED TET
11.0 mm
(7/16”)
•
•
•
•
•
•
•
-40 (ø 12.7 mm)
•
•
•
•
•
•
•
•
14.0 mm
(9/16”)
-10 (ø 6.4 mm)
TET TED TET
-12 (ø 7.1 mm)
-15 (ø 7.5 mm)
-17 (ø 8.4 mm)
-22 (ø 9.5 mm)
-30 (ø 11.1 mm)
-48 (ø 14.3 mm)
108 mm
(4 1/4”)
87 mm
(3 7/16”)
10.0 mm
(13/32”)
11.3 mm
(7/16”)
71 mm
(2 13/16”)
12.4 mm
(1/2”)
13.1 mm
(17/32”)
72 mm
(2 27/32”)
12.9 mm
(1/2”)
76 mm
(3”)
12.4 mm
(1/2”)
13.1 mm
(17/32”)
72 mm
(2 27/32”)
16.0 mm
(5/8”)
89 mm
(3 1/2”)
15.7 mm
(5/8”)
––
16.3 mm
(5/8”)
82 mm
(3 7/32”)
–
15.7 mm
(5/8”)
–
––––
16.3 mm
(5/8”)
82 mm
(3 7/32”)
16.0 mm
(5/8”)
19.2 mm
(3/4”)
18.8 mm
(3/4”)
19.4 mm
(3/4”)
99 mm
(3 29/32”)
20.0 mm
(25/32”)
22.4 mm
(7/8”)
21.8 mm
(7/8”)
22.6 mm
(29/32”)
111 mm
(4 3/8”)
23.0 mm
(29/32”)
25.7 mm
(1”)
123 mm
(4 27/32”)
25.1 mm
(1”)
22.8 mm
(29/32”)
122 mm
(4 13/16”)
26.0 mm
(1 1/32”)
14.0 mm
(9/16”)
10.0 mm
(13/32”)
11.0 mm
(7/16”)
14.0 mm
(9/16”)
14.0 mm
(9/16”)
17.0 mm
(21/32”)
19.5 mm
(3/4”)
22.0 mm
(7/8”)
25.0 mm
(1”)
16.0 mm
(5/8”)
11.3 mm
(7/16”)
13.1 mm
(17/32”)
16.0 mm
(5/8”)
16.0 mm
(5/8”)
19.3 mm
(3/4”)
22.6 mm
(29/32”)
25.7 mm
(1”)
29.0 mm
(1 1/8”)
80 mm
(3 5/32”)
62 mm
(2 7/16”)
68 mm
(2 11/16”)
86 mm
(3 3/8”)
80 mm
(3 5/32”)
100 mm
(3 15/16”)
115 mm
(4 17/32”)
129 mm
(5 1/16”)
146 mm
(5 3/4”)
29.0 mm
(1 1/8”)
139 mm
(5 15/32”)
28.2 mm
(1 1/8”)
29.0 mm
(1 1/8”)
127 mm
(5”)
Navtec
(Marine Eye)
TET TED TET
(MYN)
1
(RFE)
•
•
•
•
•
•
•
•
•
400 S
•
•
•
–
•
–
•
•
•
•
•
•
200 S
FL
Without
rigg.
screw
12
3.5 Calculating the length of the rod forestay
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. However, if the forestay rigging screw setting has to be adjusted, measure the length or
mark the original setting.
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 the rigging screw was adjusted, return it to its original setting.)
5. Measure the forestay length (FL) with just enough tension to keep it straight.
6. Enter the measurement in ”Calculation Table 1” below, under the heading “Your forestay”, on the
row marked FL.
7. Calculate the new rod length WL in ”Calculation Table 1”. Refer to the column marked ”exam-
ple” to see how this is done.
•
•
–
•
–
•
–
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
–
•
3.5.1
500 S
-40 (ø 12,7 mm)
Rod diameter
T
Calculation Table 1: Length of rod forestay
Existing forestay length (FL),
including rigging screw (See Fig. 3.5.a)
=
+
12.810
See fig 3.5.a
13.000
If links or extra toggles are to be used,
deduct this length (H) from FL. (See table 3.3.3.)
=
Your
forestay
Example
(Navtec -8)
with rigging
screw
50% extended
H
WL
Deduction for lower wire terminal:
-- 190
= 13100
Addition for cold-heading of rod forestay
(acc. to rod supplier’s data)
+
Deduction for top terminal (acc. to rod supplier’s data) --
Cutting measurement of rod
=
190
-48 (ø 14,3 mm)
With rigg.
screw
325 mm
(12 7/8”)
190 mm
(7 1/2”)
325 mm
(12 7/8”)
190 mm
(7 1/2”)
230 mm
(9 1/16”)
130 mm
(5 1/8”)
230 mm
(9 1/16”)
130 mm
(5 1/8”)
235 mm
(9 1/4”)
130 mm
(5 1/8”)
235 mm
(9 1/4”)
130 mm
(5 1/8”)
300 S
-15 (ø 7,5 mm)
-12 (ø 7,1 mm)
-22 (ø 9,5 mm)
-17 (ø 8,4 mm)
-8 (ø 5,7 mm)
190 mm
(7 1/2”)
BSI
Navtec
OYS
(Riggarna)
-10 (ø 6,4 mm)
-12 (ø 7,1 mm)
-15 (ø 7,5 mm)
110 mm
(4 5/16”)
110 mm
(4 5/16”)
190 mm
(7 1/2”)
110 mm
(4 5/16”)
190 mm
(7 1/2”)
110 mm
(4 5/16”)
190 mm
(7 1/2”)
-40 (ø 12,7 mm)
-30 (ø 11,1 mm)
190 mm
(7 1/2”)
325 mm
(12 7/8”)
190 mm
(7 1/2”)
325 mm
(12 7/8”)
200 S
300 S
C+D
400 S
C
Your
extrusion
13
3.6.1
12.810
1.270
11.540
9.600
1.940
WL
Length of new rod forestay (as per ”Calculation Table 1”)
3.6 Calculating the length of the luff extrusion
1. Insert the length of the new rod forestay (WL) as calculated in
”Calculation Table 1” into ”Calculation 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):
Check that length of terminal part of stay matches the measurement in 3.3.2.
A+B
-
=1395
=
- 12.810
C+D=
(4 sections)
-
500 S
C
Deduct from the C measurement: 200/300 S: 400 mm (15 3/4”)
400 S: 700 mm (27 9/16”)
500 S: 2800 mm (110”)
Add to the D measurement: 200/300 S: 400 mm (15 3/4”)
400 S: 700 mm (27 9/16”)
500 S: 2800 mm (110”)
D
Max. no. of 2400 mm (94 1/2”) extrusions whitch together
are shorter than C+D: [ ............x 2400 = C ] C=
Length of top extrusion =
The top extrusion is normally cut from the 2000 mm (78 3/4”)(400 S 1700 mm
(67”)) extrusion. Round the edges of the cut end using a file.
If the top extrusion is shorter than 400 mm (15 3/4”) (200/300 S), 700 mm (27
9/16”) (400 S), 1000 mm (39 3/8”) (500 S), the joint will be too near the top. In
this case replace the uppermost full-length 2400 mm (500 S: 4800 mm) extrusion with the 2000 mm (78 3/4”) (400 S: 1700 mm (67”)) extrusion. In this way
the joint is moved 400 mm (15 3/4”) (400 S: 700 mm (27 9/16”); 500 S: 2800 mm
(110”)) down the stay.
Adjust the C and D measurements as follows:
-
1395
Max. no. of 4800 mm (189”) extrusions whitch together
are shorter than C+D: [ ............x 4800 = C ] C=
-
1395
== 2115
Cont. on next page
Calculation Table 2: Length of luff extrusion
Example
(Navtec -8)
with
rigging screw
50% extended
1310 mm
(51 1/2”)
•
•
–
•
–
•
–
•
•
•
•
•
1310 mm
(51 1/2”)
•
•
•
–
•
–
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
–
•
Rod diameter
OYS
(Riggarna)
BSI
With
rigg.
screw
Without
rigg.
screw
Navtec
With
rigg.
screw
1310 mm
(51 1/2”)
1340 mm
(52 3/4”)
1290 mm
(50 3/4”)
1290 mm
(50 3/4”)
1290 mm
(50 3/4”)
Without
rigg.
screw
1320 mm
(52”)
1270 mm
(50”)
1320 mm
(52”)
1270 mm
(50”)
1320 mm
(52”)
1270 mm
(50”)
–
–
1400 mm
(55 1/8”)
1340 mm
(52 3/4”)
–
–
1400 mm
(55 1/8”)
1400 mm
(55 1/8”)
1340 mm
(52 3/4”)
1340 mm
(52 3/4”)
1340 mm
(52 3/4”)
1340 mm
(52 3/4”)
1340 mm
(52 3/4”)
1290 mm
(50 3/4”)
1340 mm
(52 3/4”)
1340 mm
(52 3/4”)
1410 mm
(55 1/2”)
1410 mm
(55 1/2”)
1340 mm
(52 3/4”)
1410 mm
(55 1/2”)
1340 mm
(52 3/4”)
1410 mm
(55 1/2”)
1340 mm
(52 3/4”)
1450 mm
(57”)
1395 mm
(55”)
1395 mm
(55”)
1395 mm
(55”)
1310 mm
(51 1/2”)
1450 mm
(57”)
1340 mm
(52 3/4”)
1470 mm
(58”)
1380 mm
(54 1/2”)
1470 mm
(58”)
1380 mm
(54 1/2”)
1395 mm
(55”)
-40 (ø 12,7 mm)
-48 (ø 14,3 mm)
500 S
-15 (ø 7,5 mm)
-12 (ø 7,1 mm)
-22 (ø 9,5 mm)
-17 (ø 8,4 mm)
-8 (ø 5,7 mm)
400 S
-10 (ø 6,4 mm)
-12 (ø 7,1 mm)
-15 (ø 7,5 mm)
-40 (ø 12,7 mm)
-30 (ø 11,1 mm)
14
Fig:3.5.a
FL = existing forestay length
A
E
C
B
D
WL
T
S
300 S
-15 (ø 7,5 mm)
E = D - 150 mm (6”)
Calculation Table 2: Length of luff extrusion, cont.
15
3.6.1
Deduction:
-
Cut the distance tube for the top extrusion in accordance
with the following fixed deduction:
E
Length of distance tube E =
-
=
Your
extrusion
Example
(Navtec -8)
with
rigging screw
50% extended
=
100
1.840
•
•
–
•
–
•
–
•
•
•
•
•
200 S
Rod diameter
•
•
•
–
•
–
•
•
•
•
•
•
E = D - 100 mm (4”)
E = D - 125 mm (5”)
E = D - 150 mm (6”)
-40 (ø 12,7 mm)
-48 (ø 14,3 mm)
500 S
-15 (ø 7,5 mm)
-12 (ø 7,1 mm)
-22 (ø 9,5 mm)
-17 (ø 8,4 mm)
-8 (ø 5,7 mm)
400 S
-10 (ø 6,4 mm)
-12 (ø 7,1 mm)
-40 (ø 12,7 mm)
-30 (ø 11,1 mm)
Navtec OYS
(Riggarna)
BSI
•
•
•
•
•
•
•
•
•
•
–
•
16
4 Assembly of the Furlex-system
4.1 Assembly of the rod forestay
Assembly is carried out by the rod supplier. Apart from the actual rod forestay, only the joining sleeve
pack is required.
1. Measure the length of the rod forestay. (The WL measurement and corrections for the length of the
top terminal and the cold-headed head at the lower end have been calculated in
”Calculation Table 1”.)
2. Cut the stay.
3. Form the head for the upper terminal and fit it. The eye part must only be fitted temporarily. Fasten
any locking screws and attach the instructions for permanent assembly of the eye part.
4.
Fig: 4.1.a
400 S
500 S
Bearing plug
5. Cold-head the head of the rod forestay for the lower bearing part.
6. Pack the stay, enclosing the completed ”Calculation Tables 1 & 2”.
Thread the joining sleeve sections on in the following order counting from the top:
• Short joining sleeves with accompanying insulation tubes. The number must correspond to the
number of 2400 mm (94 1/2”) extrusions. (500 S: 48 000 mm). See ”Calculation Table 2”,
row C, section 3.6.1.
• The long joining sleeve with accompanying insulation tube. Locking pin hole (200 S & 300 S)
towards socket.
• 400 S & 500 S: Bearing plug. Be sure to turn it as shown in the diagram.
• The socket. Be sure to turn it as shown in the diagram.
• Seat. Be sure to turn it as shown in the diagram. 500 S: Socket and seat forms one part.
17
4.2 Assembly of the luff extrusion
200 S & 300 S:
Assembly should be carried out on a horizontal surface.
1. Unscrew the eye part of the upper terminal. Wind tape around the exposed thread of the male part to
protect it.
2. Each extrusion must be pushed on over the short joining sleeves from the upper end of the stay in
turn. Push the short joining sleeves up towards the upper end terminal and secure them in position
temporarily with tape around the stay.
Push the 1000 mm (39 3/8”) luff extrusion over all the short joining sleeves and partly over the
long, lowest joining sleeve.
Fit the long connecting plate at the same time as the sail feeder as shown in the diagram. Push the
joining sleeve up so that it is flush with the top edge of the sail feeder.
Connect the 2400 mm (94 1/2”) extrusion to the 1000 mm (39 3/8”) extrusion. Push the long joining sleeve of the 1000 mm (39 3/8”) extrusion into the 2400 mm (94 1/2”) extrusion until it lies
flush with the lower edge of the 1000 mm (39 3/8”) extrusion.
Fig: 4.2.a
Fig: 4.2.b
Fig: 4.2.c
3.
4.
5.
18
Fig: 4.2.e
Fig: 4.2.f
7.
8.
Fig: 4.2.g
9.
Insert the locking pin together with the locking adhesive. Secure the pin with a piece of adhesive
tape. (The tape is removed when the lower bearing assembly is slid on.)
NOTE: Do not allow locking adhesive to come into contact with the skin! Fit a slotted distance
tube on the rod forestay and push it into the 2400 mm (94 1/2”) luff extrusion.
Fig: 4.2.d
6.
Release the lowest joining sleeve by the upper end terminal and secure the remaining sleeves again.
Slide the next 2400 mm (94 1/2”) extrusion over the rod’s top, then fit the joining sleeve andconnecting plate into it’s lower end. Connect this to the lower extrusions. Fit a distance tube onto the
rod and push it into the 2400 mm (94 1/2”) extrusion. Release the next joining sleeve, and push 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 in the same
manner.
Fit the uppermost, cut distance tube. Push the distance tube from the top until the joining sleeve
touches the distance tube below the join. The top edge of the top distance tube should now be
roughly flush with the top edge of the extrusion.
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 two pre-fitted
screws. Tighten the screws until they bottom, but do not over-tighten.
contiue on page 21.
19
4.2 Assembly of the luff section
400 S & 500 S:
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. 4.2.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:
1. Unscrew the eye part of the upper terminal. Wind tape around the exposed thread of the male part
to protect it.
2. Each extrusion must be pushed on over the short joining sleeves from the upper end of the stay in
turn. Push the short joining sleeves up towards the upper end terminal and secure them in position
temporarily with tape around the stay.
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.
Connect a 2400 mm (94”) to the 1000 mm (39 3/8") extrusion. Push the bearing plug and the long
joining sleeve up so that the holes in the 1000 mm extrusion are aligned with the holes in the bearing plug.
Fig: 4.2.a
Fig: 4.2.b
Fig: 4.2.c
3.
4.
5.
20
Fig: 4.2.e
Fig: 4.2.f
7.
8.
Fig: 4.2.g, 500 SFig: 4.2.g, 400 S
9.
Puch the bushes into the 1000 mm extrusion/bearing plug.
Fit a slotted distance tube on the rod forestay and push it into the 2400 mm (94 1/2”) luff extrusion.
Fig: 4.2.d
6.
Release the lowest joining sleeve by the upper end terminal and secure the remaining sleeves again.
Slide the next 2400 mm (94 1/2”) extrusion over the rod’s top, then fit the joining sleeve and connecting plate into it’s lower end. Connect this to the lower extrusions. Fit a distance tube onto the
rod and push it into the 2400 mm (94 1/2”) extrusion. Release the next joining sleeve, and push 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 in the same
manner.
Fit the uppermost, cut distance tube. Push the distance tube from the top until the joining sleeve
touches the distance tube below the join. The top edge of the top distance tube should now be
roughly flush with the top edge of the extrusion.
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.
21
14.2
Furlex rigging screw:
No spacer bush.
14.1 200 S & 300 S
Terminal part:
Press spacer bush over wire.
Screw out the socket on the lower terminal part and remove the wedge and former. These three
parts are no longer required. Put 2–3 drops of locking adhesive on the thread and screw the terminal together. Check that the rod head sits correctly in the seat and that the seat is in the socket correctly. Tighten it securely. This is now permanently locked.
12. Fit the eye part of the upper end terminal permanently with locking adhesive + any stop
screw/locking pin supplied.
13. Check the stay length FL in ”Calculation Table 1” (3.5.1) & Fig. 3.5.a. If a Furlex rigging screw
is fitted, this should be extended 50%. See table 14.1.1 for Furlex rigging screw adjustment.
Fig: 4.2.i
11.
Fig: 4.2.j
Fig: 4.2 k
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.
Fig: 4.2.h
10.
22
17.2. Only 400 S wire Ø12 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.
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 and 500 S:
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 assembly matches the flat faces, it will securely lock the rigging screw.
Fig: 4.2.o
Fig: 4.2.n
16. 400 S & 500 S
17.1
Fig: 4.2.m
Furlex rigging screw:
If a Furlex rigging screw is used, the flat faces of all three
parts must be aligned. As the inside of the lower bearing
assembly matches the flat faces, it will lock the rigging screw
when assembled. When fitting the Furlex, the rigging screw
should be unscrewed half-way.
15.2
Terminal part:
Guide the lower bearing assembly down over
the spacer bush and terminal part. The inside
of the lower bearing assembly matches the
flat face on the terminal part.
Fig: 4.2.l
15.1
23
20°
21. We recommend fitting the Furlex-system onto the boat at this stage. See Chapter 16, ”Rigging”.
”Manual Furlex 200 S & 300 S” (ref. no. 595-104-E). resp ”Manual Furlex 400 S & 500 S” (ref.
no. 595-116-E).
Fig: 4.2.s
Fig: 4.2.t
2
2
19.b. 400 S & 500 S
1
19.a. 200 S & 300 S
Position the extrusion so that its holes are
aligned with the adapter holes. Insert the two
screws into the adapter connecting the
lower bearing assembly to the forestay section. Use the Torx spanner set enclosed with
the Furlex kit. T
ighten the screws firmly!
Fit the clevis pin and split pin.
The shanks of the split pin are
only opened approx. 20° ensuring that the pin remains intact
on disassembly and could be reused.
Fig: 4.2.p
Fig: 4.2.q
18.
Fig: 4.2.r
1
1
1
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 to tighten the screws hard!
1
2
24
3.
2.
1.
4.3 Fitting the line drum and line guide –
200 S & 300 S
The line drum consists of two halves. It is easier to fit after the Furlex stay is fitted to the mast.
Feed the furling line through the hole in the line
guide fitting and then through the hole in the
line drum half which has a clip fitted.
Undo the clip andinsert the line into the
oval space as shown in the diagram. Fasten the clip securely, but do not overtighten.
Fig: 4.3.a
Fig: 4.3.b
Fig: 4.3.c
Cont.on page 26.
Fasten the line guide fitting in the line guard
and bring this up into the assembly position.
Tighten the screws in the stainless steel
housing.
Slide the line guard on in the direction of the
clevis pin. Press the locking block in from
underneath (Arrow 2) on the opposite side so
that it “clips” firmly into place.
Fig: 4.3.d
2
4. 5.
2
2
1
2
1
Press the line drum halves together around the
lower bearing assembly. Each flange must align
with the cut-out in the lower bearing assembly.
Check that both connector clips engage.
25
Fasten the line guide fitting to the line guard
casing using the screws enclosed.
Start by first fitting the line drum half with the line
onto the lower bearing assembly. Tighten the screws
securely, thus locking the furling line. Check that
the end of the line is visible through the inspection
hole; if not, separate the line drum halves and put
the line in position as shown in Fig. 4.3.b.
4.3 Fitting the line drum and line guide –
400 S & 500 S
The line drum consists of two halves. These are easier to fit after the Furlex is fitted to the boat.
Feed the furling line through the hole in the line
guide fitting and then through the hole in one
of the line drum halves.
Bend the end of the line down so that it
covers the inspection hole in the line
drum half.
Fig: 4.3.a
Fig: 4.3.b
Fig: 4.3.c
Fig: 4.3.i
Slide the line guard on in the direction of the
clevis pin.
Fig: 4.3.d
4.2
1
4.1
1
1
1.
2.
3.
26
Adjust the line guide vertically so that it is midway
between the line drum flanges. If the casing or line
guard come into contact with the line drum flanges,
unnecessary friction will be caused.
Tighten the screw lightly.
Adjust the alignment of the line guide towards the
first lead block and tighten screw. (See also ”Furling
line arrangement”. Chapter 6.3, in ”Manual Furlex
400 S & 500 S” (ref. no. 595-116-E).
Fig: 4.3.g
Fig: 4.3.h
3
3
Fig: 4.3.f
Fig: 4.3.e
5.
2
2
1
Push the locking block in until it rests against
the lower bearing assembly. Fasten the line guide
fitting in the line guard and bring this up into the
assembly position. Tighten the screws in the
stainless steel housing.
2
7.
6.
8.
27
17.7 Luff extrusion system
For a better understanding of the following instructions, we recommend that you first read the section
on assembly in Chapter 4.1.
1. Make sure that the luff extrusions are straight and placed on a flat surface.
2. Unfasten the lower bearing assembly as shown in 17.5, 1, 2 and 3.
3. Take the spacer bush off by pressing the stay out of the longitudinal slot.
(Only applies to Furlex 200 S & 300 S without rigging screw.)
4. Unfasten the terminal part (or Furlex rigging screw)
from the socket as shown in 17.5.4.
5. Carefully slide the lower bearing assembly off the luff
extrusion.
6.a 200 S & 300 S: Push out the locking pin at the lower
end of the 1000 mm (39 3/8”) luff extrusion.
6.b. 400 S & 500 S: Push the wire into the luff extrusion
system until the end of the wire is approx. 50 mm (2”)
inside the 1000 mm (39 3/8”) extrusion. Knock out the bushes at the lower end of the 1000 mm
(39 3/8”) luff extrusion. See Fig: 17.7.a.
7. Hold the luff extrusion system firmly and pull the upper end terminal. This will bring the rod
forestay, joining sleeves and distance tubes out together, enabling the extrusions to be separated.
If this method does not work due to corrosion or damage, the luff extrusion system connectors
can be drilled out. Use a Ø 6 mm (15/64”) drill bit for the 200 S and a Ø 8 mm (10/32”) bit for
the 300 S, 400 S och 500 S.
17.8 Top guard
If exchanging the top guard, please remember:
Navtec -12/200 S, -22, -30, -40 and Riggarna -40, -48: The guard cannot be removed from the system
by pushing it over the top eye terminal unless the eye part of the terminal is removed first.
Navatec -48, Riggarna -22 mm: The internal flange at the top edge of the guard needs to be filed down.
Alternatively, the guard can be removed from below when dismantling the sail feeder and removing
the lower bearing assembly and halyard swivel.
17 Dismantling
17.1 Halyard swivel
See ”Manual Furlex 200 S & 300 S” (ref. no. 595-104-E) resp. ”Manual Furlex 400 S & 500 S” (art nr:
595-116-E).
Navtec -10, -12/200, -22, -30, -40 and Riggarna -9.5 mm, -40, -48.
The top guard and halyard swivel cannot be removed from the system by sliding them over the top eye
terminal unless the eye part of the terminal is removed first.
17.2 Sail feeder
17.3 Line guide
17.4 Line drum
17.5 Lower bearing assembly
See ”Manual Furlex 200 S & 300 S”
(ref. no. 595-104-E). resp
”Manual Furlex 400 S & 500 S”
(ref. no. 595-116-E).
}
Fig: 17.7.a
595-111-E / 2004-12-15 Printed in Sweden.
Seldén Mast AB, Sweden
Tel + 4 6 (0)31 69 69 00
Fax +46 (0)31 29 71 37
e-mail info@seldenmast.com
Seldén Mast Limited, UK
Tel +44 (0) 1329 504000
Fax +44 (0) 1329 504049
e-mail info@seldenmast.co.uk
Seldén Mast Inc., USA
Tel +1 843-760-6278
Fax +1 843-760-1220
e-mail info@seldenus.com
Seldén Mast A/S, DK
Tel +45 39 18 44 00
Fax +45 39 27 17 00
e-mail info@seldenmast.dk
Seldén Mid Europe B.V., NL
Tel +31 (0) 111-698 120
Fax +31 (0) 111-698 130
e-mail info@seldenmast.nl
www.seldenmast.com
Dealer:
DINGHIESKEELBOATSYAC H TS
The Seldén Group is the world’s leading manu-
facturer of masts and rigging systems in carbon
and aluminium for dinghies, keelboats and yachts.
The Group consists of Seldén Mast AB in Sweden,
Seldén Mast A/S in Denmark, Seldén Mast Ltd in
the UK, Seldén Mid Europe B.V. in the Nether-
lands and Seldén Mast Inc in the USA. Our well
known brands are Seldén and Furlex. The world-
wide success of Furlex has enabled us to build a
network of over 750 authorised dealers covering
the world’s marine markets. So wherever you sail,
you can be sure of fast access to our service,
spare parts and know-how.
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