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INSTALLATION MANUAL

Fit a Profurl Cruising (C290, C320, C350, C420, C430) or Racing (R250–R430) headsail furler to your forestay: lower-terminal options and locking devices, cutting the extrusions to length, assembling joints, swivel, drum and Wrapstop, then the furling line, sail and service – with every spare part number from the exploded views, including the below-deck SP versions.

DocumentProfurl C290–C430 & R250–R430 Furlers Installation Manual
FormatPDF · 36 pages · 3.1 MB
LanguageEnglish
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Installation ManualPDF · 36 p.C290–C430 spare parts & dimensionsPDF · 7 p.R250–R430 spare parts & dimensionsPDF · 7 p.C290SP–C430SP below-deck spare parts & dimensionsPDF · 7 p.
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SpecificationsPreparationInstallationFurling Line & SailTroubleshootingDimensionsSpare PartsProducts
Profurl C290–C430 & R250–R430 Furlers — Installation Manual

This manual is split into 3 pages: Part 1 · Part 2 → · Part 3 →

Models & Key Data

Model Forestay (spare parts drawings) Furling line Ø (recommended) Luff line Ø (finished)
C290 6 / 7* mm 6 mm 5 mm – 13/64''
C320 7 / 8* mm 6 or 8 mm 5 mm – 13/64''
C350 8 / 10* mm 8 mm 5 mm – 13/64''
C420 10 mm / 12.7* mm – 5 mm – 13/64''
C430 12.7 mm – 5 mm – 13/64''
R250 – 6 mm 5 mm – 13/64''

* Installation with swageless eye: in that case the recommended sail area of the furler and the drum capacity must be respected. R350, R420 and R430 are covered by the R-series spare parts booklet (downloads). Below-deck versions C290SP–C430SP have their own booklet.

Eye & extrusion dimensions (mm)

Model A B ØC ØD
C290 25 12 14.5 15
C320 27 12.5 14 15
C350 30 14 19.5 18.5
C420 / C430 37 16.5 23.5 25
  • Every extrusion is 2 m long; one of them (never the lower feeder extrusion, which has the opening in the groove) is cut to length.
  • Parts numbers starting with N are available from 12/2021 (R250: from 2022).
  • Warranty: 10 (ten) years from the date of purchase against parts and materials (conditions in the manual).

Preparation & Forestay Terminals

Before you start

  • Remove the forestay and assemble the system on a clean, level surface. Have the forestay checked by a skilled person: recommended forestay life is about 10 years.
  • Existing forestay: before removing it, mark the turnbuckle (or adjustment plates) setting so the original length is kept. New forestay: fit it to the boat first and mark the setting.
  • Quick overview: temporarily fit the drum mechanism (with long link plates and/or turnbuckle cylinder if any) to the bottom of the stay without the extrusions; check its height above the stem head chain plate and that all parts fit the lower terminal; measure from the top of the drum mechanism (or turnbuckle cylinder) to the lower end of the top swage terminal; then dismantle and start the permanent assembly.
  • Upper terminal: ball terminals (mainly Isomat and Z-Spars masts) need a ball-eye terminal in the mast head, a slightly shortened wire and a new toggle swage terminal. T terminals (mainly Kemp / Selden masts with fractional rig) need a new stay attachment on the mast and a toggle swage terminal.

Locking devices & link plates

  • Profurl supplies locking devices with every furler: they immobilise the pin or link plates and keep the forestay lower terminal centred in the drum mechanism. Standard (black) locking devices and short link plates are delivered as standard; stainless steel locking devices on request, or compulsorily for a fitting close to the deck (without link plates).
  • Standard locking devices: lock them by turning 1/2 turn so the arrows point upwards (towards the top of the stay). If dimension "C" is larger than 18 mm (45/64'') on C290, C320, R250 or 14 mm (35/64'') on C350, C420, C430, shorten them equally at the grooves, leaving 1 mm (1/16'') each side of the toggle.
  • Stainless steel locking devices are strongly recommended for close-to-deck fittings, forestays that can't be efficiently tensioned (cruising catamarans, old gaffers), extensive charter or blue water cruising. Re-cut the bushings if needed to centre the toggle (1 mm play), then fit screws and nylock nuts.
  • Fork-fork turnbuckle: compulsory fitting with long link plates. Add a toggle at the bottom of the forestay or turnbuckle if there is none, and compensate its length.
  • Cutting long link plates: use the punch marks, mark at the drum height, drill (8,3 mm (21/64'') if pin Ø 8 mm; 10,3 mm (13/32'') C290, C320, R250; 12,3 mm (31/64'') C350, C420, C430), cut at 15 mm minimum under the hole and trim smooth. A cleaning/passivation paste is recommended after drilling or cutting.

Assembly Sequence

Cutting the extrusions

Model G = L +
C290 41 mm / 1 39/64''
C320 27 mm / 1 1/8''
C350 32 mm / 1 17/64''
C420 32 mm / 1 17/64''
C430 32 mm / 1 17/64''
R250 37 mm / 1 29/64''

With the drum mechanism on the bottom of the stay, measure L as shown in the manual; G is the total length of extrusions. Mark, cut with a metal saw and trim smooth, then dismantle the drum mechanism again. C290 only: the extrusions have a small slot parallel to the boltrope groove which must be on the left of the groove looking up the system – check it on every extrusion and when choosing which end of the top extrusion to cut.

  1. Upper bearing holder (the one with a slot near its end): fit the stop washer in the slot, the stop screw in the luff groove and tighten; slide the cut top extrusion up the forestay, fit one 1/2 bearing, the wire, the 2nd 1/2 bearing, turn the bearing 1/4 turn and push the holder into the extrusion up to the slot.
  2. Joints: fit a bearing and the joining bearing holder on the stay, slide it into the extrusion until it stops, fit the next extrusion. Apply the threadlocker supplied at the tapping entrance and tighten the set screws between 4 and 5 N.m (35–44 lbf.in; 5 N.m / 44 lbf.in is the max torque to avoid damaging the screw). Work on a flat, clean surface with clean, dry threads; do not re-tighten once fitting on the boat is completed.
  3. Lower extrusion: fit a 1/2 bearing and 1/2 lower bearing holder into the end until it stops, push the wire aside and fit the second pair, apply threadlocker and fit both nippled screws – do not screw too hard.
  4. Halyard swivel: slide it onto the extrusions the way shown and fit the 2 shackles.
  5. Drum mechanism: check the inside of the cylinder is perfectly clean (no sand, dust). Fit it onto the lower extrusion with holes T1, T2, T3 on line with the holes in the extrusion; fit and tighten T3 first, keeping T1 and T2 aligned. Apply the glue supplied to the lower extrusion stop screws.
  6. C290 only: if the extrusions were cut too long, the lower extrusion can go deeper into the drum cylinder: screw the drilling guide into hole T1, slide the extrusions down and drill the lower extrusion 6 mm (15/64'') through the guide – don't drill too deep and don't let the lower bearing press against the lower swage terminal.
  7. Wrapstop: measure the stay wire Ø accurately, drill the Wrapstop at Ø minus 1 mm (3/64''), fit and tighten it on the wire against the swage terminal with the large diameter facing forward. The Wrapstop of C290, C320 and R250 has only 2 screws.
  8. On board: don't hoist the assembled system in strong winds, don't over-bend the extrusions, check the grub screws have not loosened in transit, and double-check the Wrapstop orientation before re-attaching the top of the stay.

Turnbuckle cylinder option (all models except C290)

  • Dismantle the drum cage connectors, the drum cage and the drum; remove the screws and the shape adapter.
  • Fit the screws and the shape adapter to the top of the turnbuckle cylinder, fit the cylinder into the drum mechanism and fit the screws. The inside of the cylinder must be perfectly clean.
  • Adjusting the turnbuckle (with cylinder or link plates): remove both locking devices and the screws at the top of the turnbuckle cylinder, lift the drum mechanism up the extrusions, adjust and secure the turnbuckle, then reassemble in reverse order.

Furling Line, Sail & Use

Furling line & sail

  • Fitting the furling line requires dismantling the drum (except C290): unscrew the drum cage connectors, drum screws and drum cage screws. Pass the line through the hole of the half drum and tie a knot small enough to sit inside the drum cavity. When refitting, place the rib of the 1/2 drum in the notch of the drum mechanism.
  • C290: pass the line through the hole of the upper drum flange and tie a knot at its end.
  • Fill the drum by turning it by hand so the sail's UV strip is outwards when furled. Position the first leading block (not supplied) for a 90° angle at mid-height of the drum. Tip: run the line on the same side as the chain locker hatch hinges.
  • Feeder: Velcro® webbing in the 1st slot, feeder on the lower extrusion with the opening downwards, webbing round the extrusion and through the 2nd slot, tightened firmly. Once the sail is up, remove the feeder and keep it on board.
  • Hoisting: halyard on the top swivel shackle, sail head on the bottom one, tack on the furler tack shackle (C290: luff tape into the groove opening). With a backstay, tension the halyard AFTER tensioning the backstay. Webbing on head and tack is recommended.

Swivel position, tack & care

  • With the halyard tensioned there must be 5 to 10 cm (2 to 4'') between the top of the halyard swivel and the top of the extrusions. Most sails stretch permanently – sailmakers should allow for it. Never let the swivel go above the extrusions.
  • C290 adjustable tack fitting: loosen the screw in the tack slide rib, slide it to the required height and re-tighten firmly. Used for a drum under deck or in the chain locker, to lift the foot clear of the life lines, or to correct a luff cut too short.
  • To reef or furl, pull the furling line with slight drag on the sheet; move the genoa cars forward when reefing. To unfurl, pull the sheet with drag on the furling line for neat coils. Never unfurl without controlling the furling line.
  • Maintenance: no special maintenance; rinse with fresh water. Never use WD 40® (or similar) on the seals in the drum or halyard swivel.
  • Threadlocker (part # 52225): irritating to eyes and respiratory system. Use above 5°c in dry weather, parts at the same temperature or warmer than ambient; 24h of polymerisation recommended.
  • Owner checks after installation: luff cut to the correct length, locking devices secured, all screws tightened, halyard tight, Wrapstop properly installed, clevis pin diameter correct for the forestay terminal.

Troubleshooting

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

Dimensions & Link Plates

Letter C290 C320 C350 C420 C430 R250
A 44 44 68 68 68 32
B 10 10 10 10 10 10
C 22 22 28 28 28 16
D 120 180 200 220 220 130
ØD1 140 200 222 242 242 150
E 79 79 103 103 140 79
F 293 461 / 575 442 / 762 442 / 808 442 / 808 460 / 731
G 96 96 125 126 170 96
Hmax 320 110 / 424 137 / 457 154 / 520 154 / 520 88 / 359
I 109 109 142 144 196 109
J 100 72 72 72 72 72
K 33 33 47 47 47 25
L 404 181 / 495 220 / 540 236 / 601 236 / 601 163 / 434
L1 18 18 20 20 20 18
M 78 64 75 75 75 68
N 25 17 21 18 18 15
P 150 157 184 203 203 133
Q 98 88 108 115 115 74
R 80 66 86 90 90 60
Tmax 29 32 42 42 42 26
U 213 199 245 262 262 165
V 66 92 105 105 105 76
W 97 97 115 115 115 97
Y 29 32 35 42 42 25
Z 10370 12160 / 12475 14215 / 14535 16230 / 16595 18230 / 18595 8127 / 8398

Values in mm, standard / with turnbuckle cylinder where they differ. Letters refer to the dimension drawings in the manual (pages 28–31); imperial conversions are printed alongside in the PDF. C430 "I" from the C-series booklet.

Medium (LM) and long (LL) link plates, mm

a b c d e f g
C290 LL 180 145 110 75 4 16 41
C320 LL / LM 340 / 180 305 / 145 270 / 110 235 / 75 4 16 41
C350 LL / LM 500 / 200 465 / 165 430 / 130 395 / 95 4 16 41
C420 LL / LM 500 / 200 465 / 165 430 / 130 395 / 95 4 16 41
C430 LL / LM 500 / 250 465 / 215 430 / 180 395 / 145 4 16 61
R250 LL / LM 340 / 180 305 / 145 270 / 110 235 / 75 4 16 41

Long and medium link plates are delivered only on demand.

Short link plates delivered as standard

C290, C320, R250 C350, C420, C430, g ≤ 40 mm C350, C420, C430, g > 40 mm
a 50 mm (1 31/32'') 55 mm (2 5/32'') 55 mm (2 5/32'')
e 4 (5/32'') 4 (5/32'') 4 (5/32'')
f 15 (19/32'') 20 (25/32'') 20 (25/32'')
g 41 (1 9/16'') 41 (1 9/16'') 61 (2 3/8'')

Exploded Views & Part Numbers

Profurl C290 to C430 and R250 furler exploded view glossary naming every component from Wrapstop to drum mechanism

Profurl C290 headsail furler spare parts exploded view with part numbers

Profurl C320 headsail furler spare parts exploded view with part numbers

Profurl C350 headsail furler spare parts exploded view with part numbers

Profurl C420 headsail furler spare parts exploded view with part numbers

Profurl C430 headsail furler spare parts exploded view with part numbers

Profurl R250 headsail furler spare parts exploded view with part numbers

Profurl R350 headsail furler spare parts exploded view with part numbers

Profurl R420 headsail furler spare parts exploded view with part numbers

Profurl R430 headsail furler spare parts exploded view with part numbers

Profurl prints that only the kit sub-assemblies (bold italic on the drawings) are sold; single parts are listed for identification. Descriptions follow the manual's glossary. C420 has two drawings: 10 mm and 12.7* mm forestay.

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

Products in this Manual