Fitting a Plastimo 406Furling System

May 2009

I recently purchased a used Plastimo 406 furlingsystem to install on Barbarella.

Before carrying out any work I downloaded theuser manual from the Internet and read it severaltimes to make myself familiar with the system andthe installation process.

Since the Genoa I received with the boat washanks-on only I have also had to buy another sailcapable of furling. It is a wee bit small, but as anewbie, this is probably a good thing.

I also decided to carry out a strip down and cleanup of the furling drum before fitting and also toadd a small block at the top end of the system toallow the replacement of the sail at a later time.

Furling Drum maintenance.

The drum is held together by only 3 long Allanbolts. When taking the drum apart, be set up andready to “catch” all the plastic ball races that willescape from the inner drum. I counted a total of68 balls, 34 for the top and 34 for the bottom.

The halyard guide is held on by a couple of smallbolts.

In Figure 1 you can see the complete assembly inpieces. Also included is the 8mm spanner that wasrequired and the 4mm allen key.

I cleaned the entire device using only warm soapywater (See figures 2 and 3).

by:Bill Green

Figure 1. Unit in pieces for cleaning

Figure 2. Before Cleaning

Figure 3. After Cleaning

This included all of the body parts and the ballraces. During assembly I used a little Vaseline tohold the balls in place on the inner drum (bottomand top) to keep them “under control”, see figures4 and 5.

The assembly of the bottom unit was then com-pleted as in figures 6 and 7.

The top rotating section of the system is sealed,do not attempt to open it (see figure 8). I alsoused warm soapy water to clean it out and thenjammed Vaseline into the ball race for lubrication.

Once the cleaning and lubrication was completed Idecided to go for the Plastimo recommendedmethod of fore-stay removal type fitting. Each ofthe furling pole parts slot and secure togetherfairly easily. I had to cut the final pole to fit myfore-stay. I carried out all of this work in my backgarden before attempting assembly on the boat.

Figure 4. Balls held in place

Figure 5. Bearing in place

Figure 6. Fitting the rope guide

Figure 7. Fitting the chain plates

Figure 8. Sealed top unit

Figure 9. Drum assembly complete

I also had to add sail slugs to the Jib since the boltrope was too large for slots in the pole. I usedplenty of lubrication on all the parts duringassembly.

Figure 10. Length cut to fit forestay

Figure 11. Drum fitted to channel

Figure 12. Push in stay with a screwdriver

Figure 13. Sail slug parts

Figure 14. Sail slug fitted on bolt rope

Figure 15. Sail slug fitted in channel

To remove and install the system on Barbarella, Imade use of the high harbour wall. I tied up theboat snugly into the corner of the harbour, andwaited for low tide. Once on hard ground Islackened off the stays and set up the mast headwith a lowering halyard (I used the mainsailhalyard), see figure 17.

To make life a little easier on the day, I alreadyhoisted (but not secured) the furling pole alone. Itis resting just forward of the anchor hatch withoutthe drum attached (see figure 18).

I strongly advise that if you are going to try this,make sure you have a couple of shipmates onhand to help keep control of the mast, as it maytry to lower to the port or starboard side duringthe process.

As you can see from the picture below, I was verylucky to have the masthead resting about a meterabove the harbour wall, perfect for working on (seefigure 20).

I used a combination of shackles to secure the topsection of the furling system to the masthead. Youcan also see the small block that I used to allow achange of the fore sail, if required, at a later date. (Ednote: This is not the way the plastimo guide says to

Figure 16. Modified shackle used here

Figure 17. Halyard used to lower mast

Figure 18. Furling channel resting on bow

Figure 19. Ready to lower mast

do it as the top fitting is supposed to be attached tothe halyard and the sail attached directly to thefitting. That way the top fitting is raised or loweredwith the sail. This seems a clever way to do it as itavoids and chance of the halyard rolling round thechannel stopping it working, which is a commonproblem. However this way the halyard will be(un)twisted on furling so may cause a problem with alarger sail fitted).

It is worth check everything else out when you havethe mast lowered in this way. I made a slightadjustment to my topping lift to give it greaterclearance of the mainsail. I also checked the andcleaned the anchor light.

Once the work was done the mast was raised andsecured by the stays.

I also added stanchion guides for the furling halyardto come back to the cockpit and a small jammingcleat to secure the halyard (see figure 21).

Once assembled and secured I tested the system onthe hard before sea trials.

In figure 22 you can also see the sail slugs usedbetween the pole and the luff of the sail when it is inthe fully unfurled position.

I hope this small document helps anyone elsethinking about adding a Plastimo furling system totheir boat.

I have since carried out a range of small adjustmentsto the luff tension and position the sail.

I have sailed the boat a couple times since fitting thesystem, so far all is working well.

Cheers, Bill.

Figure 20. Mast head resting on theHarbour wall

Figure 21. Jamming cleat for control line

Figure 22. Sail slugs visible when unfurled