While replacing our mast head, we found this....

Aug 11, 2012
26
Catalina 22 Lake Dubay
Furler cable.jpg
What to do? Any suggestion besides buying a new furler? Can we just replace the cable?
Appreciate your insights.
Patrick
 

JRacer

.
Aug 9, 2011
1,331
Beneteau 310 Cheney KS (Wichita)
Yeeeoww! Yes, you should be able to replace just the stay cable. But, some insight as to why it wore like that would be good to know before doing that. Perhaps the furler has other issues that caused it.
 

Dave Groshong

SBO Staff
Staff member
Jan 25, 2007
1,864
Catalina 22 Seattle
Yikes, the forestay should be easily replaceable, can you step back and show a little more? Do you have a halyard restrainer?
 
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Feb 8, 2014
1,300
Columbia 36 Muskegon
You may have to disassemble the furler drum but there has to be a way to extract the wire from inside the foil. Don't put the mast back up until it's fixed. Sooner rather than later it is going to part the rest of the way and drop the mast on you. By the way those Nicopress fittings are user replaceable if you have the correct crimping tool, and most West Marine and other marine stores have a bench mounted tool you can use if you buy the fittings from them.
 
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Aug 11, 2012
26
Catalina 22 Lake Dubay
Wow! You guys are awesome.
So what you are saying is that there is a "Toggle" missing from the top of the furler?
I am contacting CDI directly and will let you know what they say.
Thanks!
 
Aug 11, 2012
26
Catalina 22 Lake Dubay
Don't know what a halyard restrainer is....?
Don't know what a mast hound is...?
 
Sep 25, 2008
957
Macgregor & Island Packet VENTURE 25 & IP-38 NORTH EAST, MD
That is the result of "halyard wrap", which is when the sail is rolled up the halyard gets caught and starts to roll with the furler. This wrapping motion tries to unwrap the headstay wire. Do it enough and the strands start to break. The furler will only furl in less than a turn (unless the halyard is super loose) and get tight ( read: the furling line is way too hard to pull). This is why you don't put your furling line on a winch! If you can't furl your sail in by hand, there is a problem. A halyard restrainer is a device that is attached to the mast to keep the halyard away from the top of the furler.
 
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Apr 11, 2017
571
Catalina C22 Solomon's Island, MD
I have a CDI furler (if that's what you have), and it shouldn't be too hard to replace. When you take the drum apart, be especially aware of the multiple washers, and where they are at the base. It's important to get them back together correctly, and a little awkward sometimes - but it can be easy to get it together and have the washers wrong or missing. You should be able to buy a new forestay at Catalina Direct. Make sure to check the tension on the forestay after getting it back up. Re-winding the furling line on the drum can be a little tricky, but basically all that needs to be done is to fully wrap and furl the sail, and then attach the line to the furler drum. When you draw the sail unfurled with the sheet, the drum will rotate and draw/wrap in the roller furler line on the drum. If I remember correctly, if you over-wrap the sail by a few turns (before loading the furling line on the drum), it will ultimately give you the extra furling line on the drum needed to over-wrap the sheet a few turns around the furled sail, when you are drawing it in with the furling line. Don't forget to put cotter pins in the turnbuckle screws, or the furler can undo the turnbuckle when rotating. Good luck that you saw that ahead of time.
 
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Grotto

.
Feb 18, 2018
273
Catalina 22 Wilmington
Wow! You guys are awesome.
So what you are saying is that there is a "Toggle" missing from the top of the furler?
I am contacting CDI directly and will let you know what they say.
Thanks!
Not missing, was never on the forestay. Yours is made with a nicopress fitting and end loop. Most likely the “original” from before the roller furling was installed. The correct way would have been to get a new forestay with the correct swaged toggle at the mast end. But many user installed have it “good enough” and used the cheaper nicopress forestay they already had. The wire running through the furling foil is a separate part. Sailrite.com has the manuals as a PDF I would take the time to look at their diagram. https://www.sailrite.com/PDF/FF2-Online-Manual.pdf
 
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Feb 8, 2014
1,300
Columbia 36 Muskegon
Assuming this is a CDI furler, halyard wrap would not be an issue as the CDI uses a self contained internal halyard. Doesn't use the halyard on the mast at all. That's the beauty of the system.
Still needs a toggle to prevent point loading on the wire, and the foil had to be short enough that the Nicopress fittings don't chew up the top fitting. That doesn't appear to be an issue here.
 
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Sep 15, 2016
790
Catalina 22 Minnesota
@paddy4699 You just need to replace the stay in the furler. @Grotto gave you the link from the manual and it's not a bad job it's a good thing you caught it early. Your C22 is a masthead rig and the upper toggle is simply a type of shackle at the masthead to allow more flex in the forestay and prevent binding. More than likely you have the CDI furler as that is was 90% of the C22 that have a furler use. If you just order the stay from CD it will fit just fine including the toggle at the masthead with a roll swaged end. In the link below you can clearly see the "toggle" / "shackle" on the stay. Just make sure you order it for your year of boat. I did this last year with my '87 C22 and the new stay fit perfectly.

https://www.catalinadirect.com/shop...-rigging/shrouds/forestay-assemblyc-22-95-gt/
 
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Aug 11, 2012
26
Catalina 22 Lake Dubay
Ordered it yesterday from Catalina Direct. Thanks for all of the info...appreciated!