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597-418-E
2019-03-20
204TD & 304TD
Manual and Spare parts list
Furlex
204TD & 304TD
1

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Summarization of Contents

2 Assembly preparations
2.1 Tools
Lists required tools for assembly, including basic tools and those for Sta-lok fittings.
2.2 Mast attachment
Guides on ensuring forestay articulation at the mast top, using toggles for articulation.
2.3 Hull attachment
Details how to fit the lower bearing assembly and ensure it integrates correctly with the hull.
2.4 Location of the through-deck hole
Explains how to accurately determine and mark the position for the through-deck hole.
2.5 Calculating the length of the forestay wire
Provides a step-by-step guide and table for calculating the correct forestay wire length.
2.6 Calculating the length of the luff extrusion
Guides on calculating and cutting the luff extrusion and distance tube lengths based on forestay wire.
3 Assembly of the Furlex system
3.1 Making deck hole and fitting of through-deck fitting
Instructions for cutting the deck hole and correctly fitting the through-deck fitting.
3.2 Fitting of the lower bearing assembly to the boat
Details on attaching the lower bearing assembly to the deck fitting using specific adjustments.
3.3 Fitting the furling line
Step-by-step guide for feeding and securing the furling line onto the drum.
3.4 Fitting the brims, the line guide fitting and cover
Instructions for assembling the brims, line guide, and cover onto the drum unit.
4 Assembly
4.1 Assembly of the luff extrusion
Guides on assembling the luff extrusion sections, distance tubes, and connectors onto the forestay.
4.2 Fitting the Sta-lok eye terminal (with or without rigging screw)
Detailed instructions for installing the Sta-lok terminal onto the forestay wire.
4.3 Fitting eye terminal to swaged stud (Stud/Eye)
Steps for fitting an eye terminal to a swaged stud on the forestay.
4.4 Fitting lower eye terminal to rod stay
Instructions for attaching a lower eye terminal to a rod forestay.
5 Rigging
5.1 Fitting the Furlex on a stepped mast
Steps for rigging the Furlex system to a mast that is already stepped.
5.2 Stepping the mast with Furlex fitted
Instructions for stepping the mast after the Furlex system has been fitted.
5.3 Routing the furling line
Guidance on the optimal routing of the furling line from the drum to the cockpit.
5.4 Fitting the stanchion blocks
Details on how to fit the articulating and fixed stanchion blocks for the furling line.
5.5 Fitting the stanchion blocks
Specific instructions for fitting stanchion blocks, including different types and sizes.
6 The Sail
6.1 Adapting the sail to the Furlex system
Explains necessary sail modifications and considerations for use with the Furlex system.
6.2 Adjusting the forestay length
Step-by-step guide to adjust the forestay length using the integrated rigging screw.
6.3 Checklist
A checklist to ensure all critical steps for safe and reliable Furlex function are completed.
6.4 Hoisting the sail
Detailed procedure for hoisting the sail correctly with the Furlex system.
6.5 Unfurling the sail
Instructions on how to safely and efficiently unfurl the sail.
6.6 Furling the sail
Guidance on how to furl the sail tightly and securely.
6.7 Reefing
Explains the reefing process and the "Free turn" function for sail flattening.
6.8 Racing
Describes how to convert the Furlex for twin-groove racing headfoil use.
7 Maintenance
7.1 Inspection
Recommends annual inspection of luff extrusion, bearings, and halyard leads for wear.
7.2 Service
Details on washing, rinsing, polishing, and lubricating the Furlex system.
7.3 Storage
Advice on proper storage of the Furlex system, especially regarding moisture and temperature.
7.4 Dismantling
General warning about dismantling and instructions for specific parts like sail feeder and line cover.
7.4.5 Disconnecting the forestay
Steps to safely disconnect the forestay from the lower bearing assembly.
7.4.6 Sta-lok-terminal
Instructions for removing the Sta-lok terminal from the forestay wire.
7.4.7 Stud/eye terminal
Steps for dismantling the stud/eye terminal from the forestay.
7.4.8 Top guard
Instructions for removing the top guard halves.
7.4.9 Halyard swivel
Procedure for removing the halyard swivel from the system.
7.4.10 Luff extrusion
Steps for dismantling the luff extrusion sections and joining sleeves.
7.5 Trouble shooting
A guide to common problems, their probable causes, and recommended actions.
8 Spare parts and accessories
8.1 Spare parts and accessories
Lists part numbers and dimensions for various Furlex 204TD and 304TD components.
Luff extrusion pack 204TD
Details of luff extrusion packs for 204TD, including dimensions and article numbers.
Luff extrusion pack 304TD
Details of luff extrusion packs for 304TD, including dimensions and article numbers.
Single luff extrusion pack 204TD
Contains single luff extrusion pack details for 204TD with dimensions and article numbers.
Single luff extrusion pack 304TD
Contains single luff extrusion pack details for 304TD with dimensions and article numbers.
8.2 Toggles (Forestay mast attachment only)
Provides dimensions and article numbers for eye/fork and fork/fork toggles based on forestay size.

Table of Contents