Harken Mk 1 furler repair

[tmjb]

When lowering my genoa for winter storage somehow two of the foil sections separated (or had previously separated) and the genoa jammed in the foil. Luckily I was able to free it by re-hoisting but now I have to reattach to two sections of foil - or replace the furler. I am hoping that I might be able to get some advice re the repair option on the following questions:

The foil sections appear to have been joined by 'roll pins'. Does anyone know the size, availability (can I use generic roll pins), ability to remove and replace them without the 'hammering jig' (or ability to source one)?

Assuming that I can get the material for the repair, can I access and do this by disconnecting the bottom of the furler and pulling the foil close to the mast (top still connected) where I can reach it from a bosun's chair, or do I need to drop the furler to the ground? If the latter, how do I/can I keep the foils from buckling when I do so if working alone?

I also have a question about the sail: When it jammed in the foil it tore a small amount of the cloth around the rope in the luff. Is this repairable or does the entire rope luff need to be replaced?

Thanks in advance for any input re the above.

 

[kappykaplan]

It may be a challenge to find parts for such an old furler.

When it jammed in the foil it tore a small amount of the cloth around the rope in the luff. Is this repairable or does the entire rope luff need to be replaced?

Take the sail to your local sail loft to see if the luff cloth can be repaired.

 

[tmjb]

It may be a challenge to find parts for such an old furler.

Take the sail to your local sail loft to see if the luff cloth can be repaired.

Thanks for the input. I appreciate the input.

I think that the only part I need is a roll pin, so if I was able to remove the old - and knew or could figure out the size (appear to be about 3/32" - 1/8" x 3/4") and get to it I'd be OK re the furler.

 

[kloudie1]

I bought a roll pin kit with instructions from Harken a few years ago; they are probably still available. They recommend using Loctite to hold the pins in place. If the head stay is a bit loose, furling in a heavy wind makes the foil joints work kinda like a universal joint instead of just rotating; that loosens the pins and makes them pull out.

 

[kloudie1]

Found my files:

 

[tmjb]

Thank you so much Kloudie1. This is incredibly helpful. I really appreciate it. Unfortunately I have not been able to find a roll pin replacement kit or the H825 roll pins yet. I'll keep looking.

Did you use the kit and do you have nay advice regarding my question about whether I can fix this joint by just disconnecting the bottom of the furler or need to take it down etc?

 

[jssailem]

In working with my rigger to install the MarkIV furler on my boat, we removed the forestay and furler from the boat and worked on it stretched out on saw horses and a work table. The table was moved along the furler extrusion as we glued the joints and installed the pins at each of the joints. The mast was held in place by use of the jib halyard. This replaced the forestay.
I had two extra halyards on the mast. One was used to climb the mast the second served duty as the safety line.

The reason you take it down is you need to work with both the extrusions and the forestay in the furler.

That is what I learned.

How do you get the forestay to run through the furler extrusion and the connectors without hanging up?

 

[tmjb]

Many thanks for the input John. My furler is already in place with the forestay running through the extrusions and connectors. I just have to reattach one joint that separated about 16' up from the tack. I am concerned about damaging the furler (buckling the foils) by taking it down by myself and I recently moved so have not yet found a rigger who would work with me where I am now - and the yard will charge me a fortune if I go through them. I do want to replace my standing rigging and furler in the relatively near future but prefer not to do so right now if I can help it.

 

[jssailem]

Well you may be able to get up the 16ft to resolve the issue. But it will be a hassle.
You put locktite on the joint pieces to glue the extrusions in place. (I can see the glue feeling the effect of gravity)
Then you place the pins through the holes and punch lock the edge of the aluminum extrusion over the pin. (I am not sure how you get a solid surface to manage the punch.)
Doing that while in the air will be tricky.
If you are hanging in a bosun chair I do not see a good outcome.

 

[tmjb]

Thanks again John. Yes, I am probably kidding myself... and I assume that it is not practical for em to drop and raise the furler by myself(?)

 

[kloudie1]

tmjb.. I think that the foil can be removed from the forestay once the turnbuckle inside the drum is removed. I attempted to do this myself with the boat in the water and quickly realized that I'd probably lose 50% of the parts overboard. Sat and re-thunk.. Decided that a web band around the headstay and loosely around the guy in the bosuns chair would work.. It stabilized things so that we were able to re-pin the one that had come loose and check the others. not easy, but quicker than pulling the mast. Headstay remains attached and tensioned as normal.

 

[tmjb]

Thanks so much again Claude. So the person on the bosun's chair (rigger?) pulled themselves over to the foil/headstay with the web band? If so, that's what I was considering originally but was concerned about distorting the foil too much from the pull. How high up was the joint you were trying to fix? Mine is about 16' above the tack which is about 1/3 of the luff length I think.

Any chance you still have some of the parts of the roll pin kit that I could buy from you - or even rent the hammering jig and confirm the length (3/4"? 7/8") of the 3/32" roll pins which I could then source elsewhere?

Did you apply Loctitite to the connectors or just the rollpins? Did you hammer the rollpins in or press them in?

By the way what year is your Hunter 34? My boat is an '81 Hunter 36.

 

[kloudie1]

Boat is a 1985 H-34.. The harken was on the boat when I bought it in 1991..
I do have some pins in the kit left over but they are on the boat which I won't be able to access until end of month-ish. The pins are stainless .. I had only two that were loose.. They had not fallen out so we were able to press them back in with large vise-grip pliers.. large channel lock pliers would work as well. Locktite red on the pins only here since none of the foils had separated. My problem was about 16-20 feet up.. a loose headstay was the cause. A woven band kinda like seat belt material passed around the front of the stay. You could pull on the band once it is on the foil section that is still on the connector to re attach.

 

[tmjb]

You've had yours much longer than I have mine. I purchased mine from the original owner in 2014. I'm guessing the furler was original. Its worked very well for me until this mishap.

End of month would be fine. Please let me know how much you want for them. You don't think the hammering jig is necessary even for pressing? Immaterial if you don't have it any more of course.

 

[tmjb]

Hello again Claude,

I was able to climb the mast on my boat yesterday and discovered that, like yours, the roll pin had fallen out at the foil joint in question.

Just wondering if you've managed to get to your boat yet and, if so, whether you managed to locate the roll pin kit?