SO40DS furling main jam

[cpetku]

So like SailBlue (when he had a 40DS), I've had problems with my mainsail jamming on deployment. The sail goes to a loft for service every year and they can't find anything stretched to explain the issue. Usually it's the leach side folds over and won't easily pull out of the mast.

Today was a really bad jam taking the better part of five hours to clear up eventually getting the foot unfurled to the tack to allow dropping the sail.

Yes it was a bad day, but I had a hint of this last week and tried deploying the main at the dock under light wind when it jammed. Nowhere near as bad as a jam while deploying on water (as ocurred last week but I was able to get it out over the course of 30 minutes while entertaining crew).

The highlight today was when the stitching on the clew webbing gave way while trying to pull out the sail using the manual winch. I know there was a lot of tension, but I didn't go overboard on the winch. I ended up using vice grips to capture the thick material of the clew (where the straps were sewn to) and spent a couple of hours jerking away at the sail to get as much out as I could. In the past I found that shock loads allow getting a jammed sail to free up.

Dropping the sail, it doesn't make a lot of sense how the last five feet at the head/top could have so much material inside left the mast and fouled. Pulling the last four or five feet of sail out the track while removing the main from the mast was really difficult.

While the sail looks reasonable on the ground and has been serviced every year (for the past 10), I'm wondering if the head is what's stretched (not the belly) causing my issue. Since the sail is probably pushing 18 years, I've decided to splurge on a new one for next year since I replaced the Genoa this spring.

Should I ask that the straps on the new sail's clew block be covered with UV blocking material to avoid damage to the thread? I didn't think we had that much issue with UV where I sail. Then again, I'm seeing thread failures on a dodger which I had remade by a small shop a few years ago.

[Charlie-Bravo]

Sounds like a horrible sail ! and it’s probably looking forward to retirement , 18 is quite a long time for a sail, ….. or perhaps a mast with mechanical issue, along with technique, has it ever glided in and out?

Not the same model, and mine is a Sparcraft mast, but you won’t regret getting a new sail, it really does transform the sailing experience, and when it glides out of the mast, reefs without a struggle, and stows back inside the mast on command your day will be full of happy memories.

The luff on my old sail stretched inches over its life, preventing proper luff tension which , along with being somewhat stretched in the belly , allowed creases in the sail quite early in the furling process, and these magnify the sail diameter inside the mast, giving problems and raising anxiety levels when reefing time came .
The new sail was made 3” shorter than the luff track for longevity, cut rather flat,  and a large UV clew cover out of matching spray hood canvas, all not very ‘racy’ …… but then I’m just cruising around.
Options presented to me at the time ordering a sail included a lighter more racy material with the added benefit that it would furl smaller and easier, also vertical batons which looked appealing, and allowing a greater sail area, but the slot in the mast didn’t look all that wide to my eyes, and the Genny provides most of the power on my rig, so a bigger main wasn’t on the list of desirable things, just an easy life sail.

Probably this it also the time to study the furling system, what arrangements / swivel are at the top?  and check for free smooth movement of the furling mech whilst the sail is off, also check your standing rigging, most furlers like quite a straight mast, they can cope with an inch , maybe a little more on your taller mast, but on the whole ‘straight is great’ . Deck sheaves and pulleys need to be really good , along with a quality furling line, any slight horribleness on these seems to magnify when under load and spoil your day.

Another option for the clew if you don’t like the idea of a sewn on cover, is to have a cover made that wraps around the mast and clew and a bit of boom when stowed , most boats spend more time moored up sun bathing than catching a tan out on the water.

Enjoy the new sail and an easy life.

CB

[moonshadow]

I agree with evaluating the furling system for bearings status etc. My original sail was dead well before the service you have had. And perhaps you are correct that the head area is stretched and it’s been gradually corrected with leech line over time and not noticed?
When I had a new main made I ordered Hydranet material. In addition to the long life expectancy it is also a much thinner and slippery material. So far after a few years it still furls easily.

[ales]

Is it really the sail that is the problem? i doubt it.
I had a similar problem despite new sail.

Two things you should consider:
1.) rig tension: if the mast is bended too much, then the furling mechanism will not run smoothly. Adjust the rig.
2.) bearing balls: this was my major problem. So I took down the sail and dismounted the furling (two screws on the side) just so that I was able to lift it a little bit and reach for the bearing balls. They are on two places. All reachable by hand. In may case the balls are 5mm in diameter. I cleaned everything and put new ones in.
Some of old ones were missing, some had a shape of a cube, not a ball.

[joedunn]

I have a different boat with in-mast furling but have had a few jams and it seems like it was my technique.  I have found a starboard tack and slight tension on the outhaul line when furling seems to minimize/eliminate the jams...

I agree with others check your in-mast furling system.  I un-stepped the mast (5-year old boat) about two weeks ago and have to send the drum and head swivel back to US Spars for a rebuild...all the ball bearings for the drum were at the mast step and the swivel seized up...This failure might be a maintenance issue, all I did was rinse with fresh water...not sure that was enough?