Main Sail Furling Line Change Out - Z Spars Mast

[ianpowolny]

I have changed out the main sail furling line a couple of times over the last 5 years. This years I lost one of the backing plates in to the mast and couldn't retrieve it. The backing plates were installed in 2008 using insulating tape.

Z Spars sent me new plates FOC and I paid for delivery.



The wide plates don't work due to an up-stand within the mast.

Lesson 1: Use a piece of wire coat hanger to hold on to the backing plates if you are removing the worm gear. I think if you don't back out the bolts completely you can get the wire in to one of the holes and trap the plate.
Lesson 2: With the worm gear removed bolt the backing plate to the outside of the mast and drill a sloppy fit hole say 6mm. Countersink the hole 12mm. This allows the use on an countersunk head M5 bolt and nyloc nut to hold the backing plate in place. I tapped the backing plate and this was unnecessary.
Lesson 3: Fill the mast void below the work area with rags or similar to stop parts falling in to the mast. I did and salvaged a small nut.



Job done and next time I won't need to wait a week for parts I hope. My job is a bit messy but I hope you can use this knowledge.

Ian

[Ray Yager]

Ian,   This is a very helpful post.  Thank you.  I am having a bugger of a time getting the coupler at the top of the furling cartridge to come apart from the furling tube.  Did you experience the same issue when you first tried to remove the furling cartridge?  Any trick here?  Thanks, Ray

[ianpowolny]

Ray, I just saw your question.

No trick to taking out the connecting bolt jus very fiddley.

Ian

[captbillh]

that should have been the factory solution from the start. thanks

[captbillh]

Does the smaller bolt opposite the finger holes come out or does one lower the whole furler rod to remove the larger lower bolt when it is by the drum opening?

[captbillh]

My model mast is a Jeanneau 41 type S0409E, REF Z702E. It has single riveted "backing blocks".  i did need to take the gooseneck bolt up and take the nylon nut off to clear the unit coming out of the mast. I took the smaller bolt out of the furler rod.
I will ship it down to Florida for refurbishing. 

[georgebj]

Hi Ian

Not sure if you can help, I have just had a similar issue with the plates in the mast, spoke to ZSars and they have them in stock but are asking £33 each... I was wondering if you had the dimensions for the part number 4069 as I can get them made at a fraction of the cost.

Many thanks in anticipation.

[talise]

George, 

They charged me for two of these and I must say I was surprised at the price.  Suppose I can't complain since I ordered them.

If no one else replies, I'll try to get the dimensions for you, but it will be about a week before I'm at the boat.

I do know the threads are M8 if that helps.

Duncan

[talise]

I had exactly the same issues as everyone else here.

I managed to break the heads off 3 or the 4 bolts due to galling of the threads and electrolytic corrosion where it touches the aluminium of the mast.   Finally got them out and re-tapped the holes M8, then made sure I used a suitably generous amount of Duralac on re-assembly.

I used Sikaflex to hold the plates in place during re-assembly, but this is a much better solution as it allows some wiggle room.

FWIW, I also had difficulty breaking the cast end caps away from rod.  Managed to get one off and left the other to it's own devices since you can service it with only one end free.

IMHO, this isn't a really great piece of engineering.  I've previously had Selden furlers and they are night and day in the way they are engineered.