Forestay Shroud
- Action: To Do List item A0169 – Obtain proper hardware to mount Profurl Basic Model B35M manual reefing-furling system per manufactures instructions.
- Action: To Do List item A0173 – Replace all turnbuckles and rigging wire.
- Completed: 25 August 2018
- Cost: $442.92
Ordered and received the following items for the forestay shroud:
| Forestay Shroud - 5/16" 1x19 316 SS cable | Q | Cost | |
| 5161x19316 | 5/16" 1x19 type 316 stainless | 50 | $148.50 |
| 12FBJ | Hayn Jaw Body Only Turnbuckles - Pin Diameter: 1/2", Wire Diameter: 5/16" Turnbuckle Length: 6.5", Thread size: 1/2-20 L.H | 1 | $68.00 |
| 136-08 | Sta-Lok Stud 5/16 X1/2" UNF Right Hand | 1 | $62.49 |
| 133-08-1/2 | Sta-Lok Eye - 5/16" and 8mm wire X 1/2" 12.5 pin | 1 | $54.22 |
| 12ERLH | Threaded Eye 1/2 pin and thread left | 1 | $19.65 |
| 12-323 | Double Jaw Toggles 1/2 pin | 1 | $53.88 |
| P039212 | Profurl THREADED CLEVIS PIN -32 10MM | 1 | $8.19 |
| 50010 | PIN WASHER D=10 C32 | 2 | $6.30 |
| 00094 | LOCKNUTS M12 FOR P40 SYTEMS AND 35 AND 42 CLEVIS PINS | 2 | $7.14 |
| 50011 | 12mm PLASTIC WASHER FOR 35, 42 CLEVIS PIN | 2 | $6.52 |
| RP122 | Rigging Pin 1/2" DIA. X 2" Grip | 1 | $8.03 |
| $442.92 |
The forestay shroud was encapsulated by a Profurl Basic Model B35M manual reefing-furling system. However, the attachment of the Profurl extension plates directly to the cranse iron mount hole violates the Profurl installation instructions. The additional parts to correct this improper installation were also ordered and received as the parts table above illustrates.
The furler rope was removed from the reefing-furling system drum. The nuts were removed from the clevis pin at the lower attach point and the Profurl extension plates slid off allowing the reefing-furling assembly to attempt to be lifted up along the forestay shroud wire. The swaged end of the old turnbuckle was jammed into base of furler which was extremely difficult to remove - this furler was NOT installed correctly. After the turnbuckle swaged end was freed, was able to loosen the threads of the turnbuckle and free it from the assembly so it could slide up the wire path.
Next, climbed the mast and removed the upper clevis pin securing the forestay furler shroud top. Removal of the rig pin that supports the double jaw toggle revealed its cotter pin had almost pulled through the metal as shown below.
Using a spare halyard rope, lowered the furler assembly to the ground. Another halyard was used to secure the mast upright.
The following pictures illustrate the connection points of the aluminum extrusions. Each connection point was fixed with four Allen head set screws. Each connection point needed to be disassembled and split apart to feed the new 5/16-inch 316 stainless steel wire through. It was extremely challenging to break the set screws free as they were most likely set in place with some type of adhesive sealant.
The original wire eye-to-eye length was about 47 feet 3 inches. The wire cut length was about 46 feet 1 inches.
With the Sta-Loc Eye terminal attached at the top of the wire, threaded the wire down through each of the aluminum extrusion connection points and used red Loctite to secure the set screws. The wire was them connected to the turnbuckle. The entire assemble was then hoisted aboard using a halyard and the top eye terminal attached to the new rig pin with new washers and cotter pins that holds the new double jaw toggle.
The cranse iron mount hole was de-burred and sanded smooth. The new double jaw toggle with 1/2 inch rig pin fit checked ok and moved without binding. The base of the furler assembly was attached to the cranse iron with a double jaw toggle and new 1/2-inch clevis and cotter pin. The top portion of the double jaw toggle had the threaded clevis pin and nuts attached with the Profurl extension plates; correcting the original improper installation - the Profurl reefing-furling system now had full articulation of movement minimizing stress loading of the installation.
