Have felt like the Furlex on my 2008 Hunter 38 has been more difficult to furl than it should be ever since we bought her new. The boat was a dealer demo and we acquired her in 2009. Not impossible but just not as smooth as it should be. Tried loosening the halyard tension a bit, tightening it a bit, unwinding the drum and rewinding it, all with no real change.
This year it reached a point where it was so difficult that I'd had enough. I was even reaching a point where I was having to put it on a winch and crank it in (yes I know this is just not right). Worked at it an finally found what was wrong. Almost embarrassed to admit it since it was so simple.
Before giving you my discovery I have to premise with - I am a manual reader. I read every instruction manual of everything I've ever bought. Maybe it is OCD but I don't assemble anything without sitting down and sorting the pieces into piles and even counting them, reading the entire assembly instructions, and then going step by step. I read every manual for every pice of equipment that came with the boat several times (or so I thought).
So imagine my embarrassment when in frustration I pulled out the manual for the Furlex and read it very carefully. Especially the section about putting the furling line on the drum. In the set up it said that if the furling line is on the starboard side of the boat the drum should be turned counterclockwise to wind the line on the drum. And if it feeds from the port side the drum should be turned clockwise to wind the line on.
Ready? Here it comes. For 5 years I've been fighting with it and just discovered that all this time the line has been rolled on backwards. My furling line is on starboard side and it was rolled on the drum with a clockwise turn. This is the way it came from the dealer. When it is rolled on backward like this, the tensioner that is inside the base of the drum doesn't apply enough pressure to evenly wrap the line on the drum. It bunches and allows overlaps which makes it miserable and difficult to roll the sail back up.
Now that it is rolled on in the correct direction, it is nice and smooth, no overlaps, no bunching and I can furl the sail with not much more than a 1 handed pull.
Embarrassed but much happier now. Guess this winter I need to sit down and read all the manuals again.
