Assembling a Flexible Furler is relatively simple and can usually be done by anyone with a #2 Phillips head screwdriver, a hacksaw and a pair of vice-grips. It can be done with the mast up or down, and, after the luff extrusion is straight, can be done by one person (though it is nice to have a helper to read the instructions while you do the work).
LUFF STRAIGHTENING INSTRUCTIONS
If you receive your Flexible Furler luff via UPS, the first part of the assembly process is to straighten the luff. (You'll notice a bright colored instruction sheet on the outside of your luff box.) This should be done within a day or two of receipt. Straightening takes three people for the FF1 and FF2 and four people for the FF4 and FF6. Strength is not required, just the number of people in order to control the long coiled extrusion.
1. Carefully remove the tape holding
the luff in a coil. (See diagram on instruction sheet.)
2. Then, pull the luff out straight, with a person at each end of the luff and the other person(s) along the middle of it. Make sure everyone's holding the luff at a constant height off the ground, and with the grooves up and down.
3. Next, bend the luff until it is in one big hoop in the direction opposite the natural bend.
4. Tape the upper end to the lower end where the natural curve starts, usually a few inches above the sail feed slot.
5. Let the luff lie on the ground in a circle. Leave it there for at least three hours, until the luff remains straight after releasing the tape. The warmer the temperature, the quicker it will come straight.
The hard part is over. Please note, if the straightening process seems ominous, CDI can ship the luff in a 6' hoop or via truck.
1. Measure the length of the forestay. Reduce that length by the amount shown in the manual and cut the luff to the resultant length.
2. Pass the internal halyard through the halyard top fitting. Slip the halyard top fitting over the upper end of the extrusion.
3. Slide the halyard top fitting/extrusion over the headstay.
4. Pass the spool over the lower end of the luff extrusion.
5. Assemble the cup, bearing and antirotation strap over the lower end of the turnbuckle using the two screws provided.
6. Reassemble the turnbuckle, attach to chainplate and slide drum into cup and over the bearing.
7. Pass the furling line into the cup and up through the hole in the upper flange of the drum. Tie an overhand knot to secure.
8. Lead furling line aft, set the sail and go sailing.
Remember, the installation manual
has more complete instructions including pictures of parts to make installation
clearer. Assembly should take no more than two hours after straightening the