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INSTALLATION MANUAL

How to fit a Profurl Basic B29 (S, L) or B35 (S, M, L) headsail furler: forestay terminal checks, drum fitting with or without long link plates, cutting and joining the extrusions, Wrapstop, furling line and sail, troubleshooting, the exploded parts drawings with part numbers and the full dimension table.

DocumentProfurl Basic B29 & B35 Furlers Installation Manual
FormatPDF · 23 pages · 1.7 MB
LanguageEnglish
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Installation ManualPDF · 23 p.B29 & B35 spare parts & dimensionsPDF · 4 p.
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Profurl Basic B29 & B35 Furlers — Installation Manual

Preparation & Forestay Checks

Before you start

  • Tools: measuring tape, adjustable spanner with 30 mm (1 3/16") opening, electric drill and a set of drills, metal saw, smooth file.
  • For easier installation remove the forestay and assemble the system on a clean, level surface.
  • Existing forestay: before removing it, mark the adjustment of the turnbuckle or adjustment plates. New forestay: fit it to the boat first and mark the adjustment. This keeps the original forestay length.
  • Have the forestay checked by a skilled person; recommended forestay life is about 10 years.

Forestay terminals

  • Ball terminals (mainly Isomat and Z Spars masts): fit a ball-eye terminal into the mast head, shorten the wire by a few inches and have a new swage terminal pressed on.
  • T terminals (mainly Kemp and Selden masts with fractional rig): fit a new stay attachment on the mast and have a toggle swage terminal pressed on.
  • Fit a toggle at the bottom of the forestay (or turnbuckle) if there is none, and compensate for its length.
  • A fork–fork turnbuckle requires fitting with Long Link Plates.
  • Locking devices (black nylon) centre the lower terminal in the drum. If dimension "C" exceeds 18 mm (Basic 29) or 14 mm (Basic 35), shorten them equally at the grooves, leaving 1 mm (1/16") each side of the toggle. Lock them with 1/2 turn so the arrows point to the top of the stay.

Assembling the Furler

Extrusions & bearings

  1. With the drum fitted at the bottom of the forestay, measure "L". Total extrusion length G = L + 30 mm (+1 3/16") on every model.
  2. Each extrusion is 2 metres long. Cut one extrusion (never the lower feeder extrusion) to obtain G, and trim the cut smooth. The small slot in every extrusion must be on the left of the boltrope groove when looking towards the top.
  3. Upper bearing holder (the one with a slot near its end): fit one 1/2 bearing, the wire, the second 1/2 bearing, turn the bearing 1/4 turn, slide the top extrusion up the stay, push the holder in up to the slot, fit the stop and tighten the stop screw.
  4. Joints: fit a bearing into each joining bearing holder, slide it into the extrusion until it stops, fit the next extrusion (check the slot), then fit the set screws just touching the holder and tighten 1/4 extra turn. Coat the threads with Loctite.
  5. Lower extrusion: fit 1/2 bearing and 1/2 lower bearing holder, centre the wire, fit the second halves and both nippled screws (Loctite on the threads).
  6. Fit the halyard swivel onto the extrusions as shown, with its 2 shackles.

Drum, Wrapstop & on board

  1. Make sure the inside of the drum cylinder is perfectly clean. Fit the drum mechanism onto the lower extrusion up to the black mark, with hole "T" in line with the hole in the extrusion; fit and tighten stop screw "U". Then fit the drum permanently to the lower end of the stay.
  2. Extrusions cut too long (only too long): slide them deeper into the cylinder, screw the drilling guide into hole "T" and drill the lower extrusion with a 6 mm (15/64") drill. Do not drill too deep, and do not let the lower bearing press on the lower swage terminal.
  3. Wrapstop: measure the wire diameter accurately, drill the Wrapstop at Ø minus 1 mm (3/64"), fit it against the upper swage terminal with the large diameter facing forward. On B29 S and B29 L it has only 2 screws.
  4. Do not install in strong winds and do not overbend the extrusions. Check the Wrapstop alignment before attaching the stay to the mast head.
  5. Turnbuckle adjustment: remove both locking devices and screws "T" and "U", slide the drum up the extrusions, adjust and lock the turnbuckle, then reassemble. Never shorten below the original length.

Furling Line, Sail & Operation

Rigging

  • Furling line diameter: B29 S 6 mm; B29 L 6 or 8 mm; B35 S 8 mm; B35 M 8 or 10 mm; B35 L 8 or 10 mm.
  • Pass the line through the hole in the upper drum flange (B29) or the centre of the drum (B35) and fill the drum by hand so the sail's UV strip ends up outside.
  • Place the first leading block (not supplied) so the line reaches the drum at 90° at mid-height and spreads evenly.
  • Halyard on the top shackle of the swivel, sail head on the bottom shackle; feed the luff tape into the groove opening while hoisting. Finished luff tape diameter: 5 mm (3/16").
  • With the halyard tensioned, the top of the swivel should sit 5 to 10 cm (2 to 4") below the top of the extrusions. Never let the swivel ride above the extrusions; sails stretch permanently with use.
  • Adjustable tack: loosen the screw in the tack slide rib, slide it to the height wanted and re-tighten firmly (drum below deck, foot clear of the lifelines, or a luff cut too short).

Use & maintenance

  • Furl or reef by pulling the furling line with a slight drag on the sheet. When reefing, move the genoa traveler forward at each stage.
  • Never unfurl without controlling the furling line.
  • No special maintenance: rinse with fresh water. Never use WD 40 (or similar) on the drum or swivel seals.

Troubleshooting

Problem Cause Remedy
System not rotating Halyard swivel badly adjusted; halyard wrapped around luff extrusions Adjust the halyard swivel; adjust the Wrapstop (seq. 51)
System hard to turn Furling blocks too small Fit larger furling blocks
System hard to turn 1st furling block badly positioned Trim position of the 1st furling block
Furling line jams the drum Furling line diameter too large Fit a thinner furling line
Furling line jams the drum Overfilled drum Furl the sail tighter and remove extra furling line coils
Furling line jams the drum Wrong direction of furling line through drum cage Change direction of furling line through the drum cage (seq. 54)

Exploded Views & Part Numbers

Profurl Basic B29 S / L spare parts exploded drawing with part numbers

B29 S / L (29 mm extrusion)

Part no. Description
P039060 Wrapstop (Multitop) View part →
P155033 Upper bearing holder assembly Ask us to source it →
50119 Upper bearing holder View part →
00051 Half bearing Ask us to source it →
00057 Self-taping screw (upper bearing holder stop) Ask us to source it →
00056 C-shaped washer (upper bearing holder stop) Ask us to source it →
P155020 Halyard swivel assembly Ask us to source it →
P155021 Halyard swivel Ask us to source it →
50120 Shackle Ask us to source it →
P155029 Halyard swivel bushings View part →
P155034 Joining bearing holder assembly Ask us to source it →
50118 Joining bearing holder View part →
05861 Set screw (extrusion joints) Ask us to source it →
P155032 Intermediate extrusion assembly Ask us to source it →
50116 Intermediate luff extrusion View part →
P155031 Lower extrusion assembly Ask us to source it →
50117 Lower extrusion View part →
05501 Nippled screw (lower bearing holder) Ask us to source it →
50370 Lower bearing holder View part →
50161 Drilling guide View part →
P146010 Drum mechanism, complete – B29 S Ask us to source it →
P155010 Drum mechanism, complete – B29 L Ask us to source it →
P155115 Adjustable tack ring assembly Ask us to source it →
50253 Screw (tack ring / drum) View part →
P146012 Drum – B29 S Ask us to source it →
P155012 Drum – B29 L Ask us to source it →
50106 Drum cage – B29 S Ask us to source it →
50107 Drum cage – B29 L Ask us to source it →
50063 Drum cage screw Ask us to source it →
P146011 Drum mechanism – B29 S View part →
P155011 Drum mechanism – B29 L Ask us to source it →
P155311 Locking devices – pin Ø8 View part →
P155312 Locking devices – pin Ø10 > 14 View part →
P155211 Optional long link plates Ask us to source it →

Also on the B29 drawing: tack ring parts 02253 and 50093; drum screws 50110 and 05872; clevis pin 50xxx; threaded clevis pin Px392x2 with parts 50009 (Ø8) / 50010 (Ø10 > 14) and 00018 (Ø8) / 01224 (Ø10 > 14). Ask us to source them.

Profurl Basic B35 S / M / L spare parts exploded drawing with part numbers

B35 S / M / L (35 mm extrusion)

Part no. Description
P035060 Wrapstop (Multitop) View part →
P153033 Upper bearing holder assembly Ask us to source it →
50066 Upper bearing holder Ask us to source it →
50172 Half bearing View part →
00057 Self-taping screw (upper bearing holder stop) Ask us to source it →
02103 C-shaped washer (upper bearing holder stop) Ask us to source it →
P153020 Halyard swivel assembly Ask us to source it →
P153021 Halyard swivel Ask us to source it →
50111 Shackle Ask us to source it →
P153029 Halyard swivel bushings Ask us to source it →
P153034 Joining bearing holder assembly Ask us to source it →
50067 Joining bearing holder Ask us to source it →
00052 Set screw (extrusion joints) Ask us to source it →
P153032 Intermediate extrusion assembly Ask us to source it →
50069 Intermediate luff extrusion Ask us to source it →
P153031 Lower extrusion assembly Ask us to source it →
50068 Lower extrusion Ask us to source it →
05501 Nippled screw (lower bearing holder) Ask us to source it →
50065 Lower bearing holder View part →
50161 Drilling guide View part →
P153010 Drum mechanism, complete – B35 S Ask us to source it →
P147010 Drum mechanism, complete – B35 M (Booklet 16; the manual drawing prints it for the L) Ask us to source it →
P151010 Drum mechanism, complete – B35 L (Booklet 16; the manual drawing prints it for the M) Ask us to source it →
P153115 Adjustable tack ring assembly Ask us to source it →
50064 Screw (tack ring / drum) Ask us to source it →
P153012 Drum – B35 S Ask us to source it →
P147012 Drum – B35 M Ask us to source it →
P151012 Drum – B35 L Ask us to source it →
50112 Drum cage – B35 S Ask us to source it →
50073 Drum cage – B35 M Ask us to source it →
50114 Drum cage – B35 L (Booklet 16; the manual prints 50014) Ask us to source it →
50063 Drum cage screw Ask us to source it →
P153011 Drum mechanism – B35 S & M Ask us to source it →
P151011 Drum mechanism – B35 L Ask us to source it →
P153311 Locking devices – pin Ø10–11,1 View part →
P153312 Locking devices – pin Ø12 > 19 Ask us to source it →
P153211 Optional long link plates Ask us to source it →

Also on the B35 drawing: tack ring parts 02253 and 50057; drum screws 50110 and 05872; clevis pin 500xx (Ø10–11,1), 020xx (Ø12 > 19) or 05510 (Ø12,7); threaded clevis pin P03x2x2 with parts 50010 (Ø10) / 50011 (Ø12 > 19) and 01224 (Ø10–11,1) / 00094 (Ø12 > 19). Ask us to source them.

Descriptions are the component names on the manual's labelled general view. Parts lists are from Booklet 16 (PDF downloads); some parts are only available until stock runs out.

Dimensions of the Basic Models

B29 S B29 L B35 S B35 M B35 L
A 45 mm / 1 49/64" 45 mm / 1 49/64" 70 mm / 2 3/4" 70 mm / 2 3/4" 70 mm / 2 3/4"
B 10 mm / 25/64" 10 mm / 25/64" 10 mm / 25/64" 10 mm / 25/64" 10 mm / 25/64"
C 20 mm / 25/32" 20 mm / 25/32" 28 mm / 1 7/64" 28 mm / 1 7/64" 28 mm / 1 7/64"
D 120 mm / 4 47/64" 150 mm / 5 29/32" 170 mm / 6 11/16" 200 mm / 7 7/8" 220 mm / 8 43/64"
E 70 mm / 2 3/4" 70 mm / 2 3/4" 98 mm / 3 55/64" 98 mm / 3 55/64" 98 mm / 3 55/64"
F 365 mm / 1' 2 3/8" 475 mm / 1' 6 11/16" 680 mm / 2' 2 23/32" 680 mm / 2' 2 23/32" 760 mm / 2' 5 7/8"
G 90 mm / 3 35/64" 90 mm / 3 35/64" 128 mm / 5 3/64" 128 mm / 5 3/64" 128 mm / 5 3/64"
H max 320 mm / 1 19/32" (as printed) 430 mm / 1' 4 15/16" 460 mm / 1' 6 3/32" 460 mm / 1' 6 3/32" 530 mm / 1' 8 7/8"
I 105 mm / 4 1/8" 105 mm / 4 1/8" 130 mm / 5 1/8" 130 mm / 5 1/8" 130 mm / 5 1/8"
J 100 mm / 3 15/16" 100 mm / 3 15/16" 150 mm / 5 29/32" 150 mm / 5 29/32" 150 mm / 5 29/32"
K 105 mm / 4 1/8" 105 mm / 4 1/8" 270 mm / 10 5/8" 270 mm / 10 5/8" 270 mm / 10 5/8"
L 400 mm / 1' 3 3/4" 510 mm / 1' 8 5/64" 540 mm / 1' 9 1/4" 540 mm / 1' 9 1/4" 610 mm / 2' 1/64"
M 75 mm / 2 61/64" 75 mm / 2 61/64" 80 mm / 3 5/32" 80 mm / 3 5/32" 80 mm / 3 5/32"
N 25 mm / 1" 25 mm / 1" 32 mm / 1 1/4" 32 mm / 1 1/4" 32 mm / 1 1/4"
O 45 mm / 1 49/64" 45 mm / 1 49/64" 50 mm / 1 31/32" 50 mm / 1 31/32" 50 mm / 1 31/32"
P 150 mm / 5 29/32" 150 mm / 5 29/32" 190 mm / 7 15/32" 190 mm / 7 15/32" 190 mm / 7 15/32"
Q 99 mm / 3 57/64" 99 mm / 3 57/64" 115 mm / 4 17/32" 115 mm / 4 17/32" 115 mm / 4 17/32"
R 80 mm / 3 5/32" 80 mm / 3 5/32" 95 mm / 3 3/4" 95 mm / 3 3/4" 95 mm / 3 3/4"
S 160 mm / 6 19/64" 255 mm / 10" 240 mm / 9 29/64" 240 mm / 9 29/64" 310 mm / 12 13/64"
T max 28 mm / 1 7/64" 28 mm / 1 7/64" 32 mm / 1 1/4" 32 mm / 1 1/4" 37 mm / 1 29/64"
U 210 mm / 8 17/64" 210 mm / 8 17/64" 265 mm / 10 7/16" 265 mm / 10 7/16" 265 mm / 10 7/16"
V 66 mm / 2 19/32" 66 mm / 2 19/32" 115 mm / 4 17/32" 115 mm / 4 17/32" 115 mm / 4 17/32"
W 97 mm / 3 13/16" 97 mm / 3 13/16" 115 mm / 4 17/32" 115 mm / 4 17/32" 115 mm / 4 17/32"
X 46 mm / 1 13/16" 46 mm / 1 13/16" 56 mm / 2 13/64" 56 mm / 2 13/64" 56 mm / 2 13/64"
Y 29 mm / 1 5/32" 29 mm / 1 5/32" 35 mm / 1 3/8" 35 mm / 1 3/8" 35 mm / 1 3/8"
a 175 mm / 6 57/64" 175 mm / 6 57/64" 203 mm / 7 63/64" 203 mm / 7 63/64" 203 mm / 7 63/64"
b 145 mm / 5 45/64" 145 mm / 5 45/64" 168 mm / 6 39/94" (as printed) 168 mm / 6 39/94" (as printed) 168 mm / 6 39/94" (as printed)
c 115 mm / 4 17/32" 115 mm / 4 17/32" 133 mm / 5 15/64" 133 mm / 5 15/64" 133 mm / 5 15/64"
d 85 mm / 3 11/32" 85 mm / 3 11/32" 98 mm / 3 55/64" 98 mm / 3 55/64" 98 mm / 3 55/64"
e 4 mm / 5/32" 4 mm / 5/32" 4 mm / 5/32" 4 mm / 5/32" 4 mm / 5/32"
f 15 mm / 19/32" 15 mm / 19/32" 17 mm / 43/64" 17 mm / 43/64" 17 mm / 43/64"
g 35 mm / 13/8" (as printed) 35 mm / 1 3/8" 45 mm / 1 25/32" 45 mm / 1 25/32" 45 mm / 1 25/32"

Lettered dimensions as printed on page 22 of the manual (drawing in the PDF); a to g are the optional long link plates.

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

Products in this Manual