Selden In-Mast Furling Reinforcement for Bavaria 40 AC — Instructions

What the Kit Does

Discontinued model – documents and spare parts as printed.

Retrofit reinforcement for the in-mast furling mast on the Bavaria 40 AC: a halyard exit reinforcement (article 507-308) and an aft reinforcement (article 507-304).

Mounting the Halyard Exit Reinforcement 507-308

1. Remove any rope clutch in the way.
2. Position 507-308 on the outside of the mast with adhesive tape (view 1, port side).
3. Drill ø 4.9 mm holes at A and B.
4. Insert pop rivets in A and B and hold them with tape. Do not rivet.
5. Drill the remaining ø 4.9 mm holes.
6. Remove 507-308.
7. Check the inner mast surface and 507-308 are free from burrs.
8. Thread a messenger line through the mast wall and 507-308 at hole C.
9. Fit the bracket on the inside of the mast wall and rivet all holes.
10. Punch all centre pins out of the rivets.

Mounting the Aft Reinforcement 507-304

1. Put a cloth through the access hole to protect the furling gear from chips.
2. Drill out the port-side boom bracket rivets with a ø6.5mm drill.
3. Mark the hole positions per PS-409 using drill template 595-174.
4. Cut a hole through the template and position 507-304 per PS-409; secure with a clamp, protecting the mast from scratches.
5. Drill holes A, B and C ø 4.9mm.
6. Tap A, B and C through mast wall and 507-304 to M6.
7. Remove 507-304 and drill A, B and C ø 6.2mm in the mast wall only.
8. Refit 507-304 and secure with M6 screws at A, B and C.
9. Drill all holes ø4.9mm, including the boom bracket holes.
10. Drill the boom bracket holes ø6.5mm.
11. Tap all ø 4.9mm holes in 507-304 to M6.
12. Remove 507-304 and drill the remaining mast holes ø 6.2mm.
13. Check mast inner surface and 507-304 are free from burrs.
14. Refit 507-304 and fit all screws with locking adhesive.
15. Fix the boom bracket with ø 6.4mm pop rivets.
16. Remove the cloth.