Southern Spars Users Manual
Contents
1. m F k A z T m Y 4 M k a 1 B I om dc s F R MAST USERS 2S MANt j To ePhoto courtesy of Jerelyn Biehl COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 SouthernSpars TABLE OF CONTENTS Q Introduction Q Care C Washdown C Paint Scratches UTravel LIRig Inspections C Quick Set Up Guide Set Up Tips UHalyard Threading ClJoining the Mast L Attaching Trapeze Lines L Attaching Stays Tuning Guide QRig Tension Updates L Retrofit Details Extra Fastener added to Top Spreader Gennaker Halyard Deflector Vang Strop Mast BOM Bill of Materials Parts List Mast Sub Assemblies BOM Parts List Rig Spare Parts Dealers Warranty About Southern Spars Flow simulation of 49er during rie development COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 Spars INTRODUCTION Southern Spars is the licensed supplier of the 49er rig The three piece male moulded mast is made from 100 standard modulus carbon and is available through licensed 49er dealers In carbonising the 49er rig the goal was to develop a rig that could be easily and accurately reproduced with an emphasis on the details that affect performance The focus was on how to achieve consistency of b2. MASTBASE SPLIT RINGS RONSTAN RF113 _ 150 0059 SCALE 154 SUB ASSEMBLY PART 590 0465 CLEVIS PIN 1 4 20 x 4 1 2 590 0473 1 4 20 NYLOC NUT SPLIT RINGS RONSTAN RF114 STAY RETAINER 080 0307 T 150 1259 322 0205 THREADED PIN 46mm 319 0023 SSS SSS SS SPSS 25 55 DETAIL C GOOSENECK BRACKET SCALE 1 2 COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 SouthernSpars RIG SPARE PARTS Available through 49er Dealers only Description Main amp jib halyards including adjustment system Tapered Spinnaker 590 0476 _HALYARD CLEAT HANGER Mon LAC Mn nn SPREADERS BAG RIGGING BAG COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 DEALERS 49er masts rigging spare parts and covers are available from the following suppliers Argentina Martin Bulloch Marine San Fernando P 54 11 4745 8428 Martin Bulloch info bulloch com www bulloch com Australia Bethwaite Design Woollahra Sailing Club Vickery Ave Rose Bay NSW 2029 Australia P 61 2 9371 6338 Clynton Wade Lehman clynton bethwaite com www bethwaite com Italy Nautivela srl via Gardone 8 Milano Italy P 39 02 55212116 F 39 02 55212116 Paolo Portiglia paolo nautivela com www nautivela com COMPOSITE SPA
3. 49er USERS MANUAL 2010 SouthernSpars 1 ih II 49er USERS MANUAL 2010 SouthernSpars MAST BOM Gem 919 z 23925 137095 A v vlv z 2 mz z miam a lz 3 x 5 8 cE COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE UD 49er USERS MANUAL 2010 SouthernSpars S9rO D69 Hrd ATBAGSSy B5 S3HvdS 43 OlISn2 DESIGN BOM MAST SUB ASSEMBLIES BOM DESCRIPTION PART No REV 49er TOP SECTION COMPLETE 49er MIDDLE SECTION COMPLETE 49er BOTTOM SECTION COMPLETE 590 0461 590 0462 590 0463 A 49er ONE PIECE SPREADER 590 0482 CLEVIS PIN 1 4 x 5 1 2 923904182 RILEY RM682 GOOSENECK TOGGLE RILEY RM679 GOOSENECK PIN HALYARD CLEAT HANGER 150 1107 150 1085 040 0372 590 0476 WASHER 6MM FLAT MMC 909654170 080 0295 SADDLE WITH EYE RONSTAN RF1058 150 1104 CLEVIS PIN 3 16 x 3 4 MMC 92390A102 150 0017 SHEAVE 16mm HARKEN 415 SHEAVE 25mm x 8mm 4986 8 CLEVIS PIN 1 4 x 7 8 MMC 92390A186 040 0859 040 0857 150 1105 CLEVIS 3 16 x 2 MMC 92390A112 150 1106 DETAIL A MASTHEAD SHEAVE 38mm HARKEN 307 BUSH MAST BASE ALLOY CASTING 040 0293 303 1346 5290 0416 SCALE Te
4. OSpanner for M5 nuts LiElectrical tape 3mm Allen Key 5 of 4mm wire as a threading guide wire HALYARD THREADING The main halyard is 3mm dynex rope with a 4mm Spectra tail Remove the sheaves in the head fitting and tie the end of the halyard to the lower clevis pin on the back of the head fitting Remove the Uppers stay bolt The main halyard is a 2 to 1 system and goes through the shackle that attaches to the head of the mainsail Once you thread the main halyard behind upper bolt and gennaker halyard infront of upper bolt through the tip section pull tight and tape into place At this point look up inside the tip section to check the halyards arent twisted Thread the jib halyard through the Harken HK 302 exit block at the top of the midsection Then thread the jib halyard through the midsection and tape into place COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 Now run the main and gennaker halyards through the midsection again pulling each halyard tight once they have gone through Check that the halyards are not twisted Thread the halyards through the bottom section and out the mastbase It is easiest to do this with the mastbase not attached to the mast The gennaker halyard exits out of the front of the mastbase The main and jib halyards exit through the back sheaves in the mastbase Before re attaching the mastbase do a final check that the halyards ar
5. top spreaders twist from tack to tack In most cases this is due to the fastenings coming loose If the fastenings ever come loose there is the risk that the holes will slightly elongate and then it will be hard to ever stop movement We suggest that all fasteners are done up firmly with Loctite thread locker to stop them coming loose during sailing To hold the spreader in place more firmly you can also add another fastener at the back of the spreader This can be fitted either under the track or inside the track Use an M5 CSK machine screw Drill a 3 4mm hole through the spreader band and then tap into the joining sleeve Again use Loctite to hold the screw firmly place Please see photos below for more information on how to do this Tap 4mm hole with M5 tap Fasten CSK M5x12mm fastener COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 SouthernSpars i GENNAKER HALYARD DEFLECTOR COMING LOOSE VANG STROP some deflectors are coming loose from the loads put on them A saddle is fitted to fix the height of the block when the gennaker is initially hoisted All new masts are being fitted with a new fitting which solves this problem If your fitting has come loose then please contact your 49er dealer and you can fit the new fitting They use the 2 holes from the old fitting plus require 1 extra rivet to be added Please see photo below of a new fitting being attached
6. AL SERVICE 49er USERS MANUAL 2010 SouthernSpars TUNING GUIDE Over time the top sailors in the class will develop and fine tune the fastest settings for the new carbon rig We will continually update the tuning guide with as much of that information as possible this will be available on our website MASTBEND The old rig went best with a straight bottom section The top section was relatively soft and this produced a dynamic response that automatically depowered the rig in gusts The new rig relies more on the square top for depowering There is less luffcurve in the top of the main so the head will open automatically in gusts to an even greater degree than the old rig To support the square head we made the top of the rig a lot stiffer The lower section of the mast is very similar stiffness to the old rig however the whole rig needs to be set up with a more even bend to get a good balance on the helm If you set up the mast straight in the lower sections like before then the boat will feel stalled at times Forget about the way the mast looked before and set up the bend so that the main looks good There will be less change in sail depth through the wind range and the main will retain a tighter leech for longer so you will probably set up the main slightly flatter than before You will need to use a lot higher vang and cunningham tensions than with the old rig Happy sailing and please email any tips or tuning information t
7. RS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 Japan Performance Sailcraft Japan 3 13 31 Ayase shi Kamitsuchitana Minami Kanagawa Ken 252 Japan P 81 467 76 1051 F 81 467 76 1052 Takao Otani psJ psjpn co jp WWW psjpn co jp New Zealand Mackay Boats Ltd 24 Manga Rd Silverdale Auckland New Zealand P 64 9 426 4306 Dave Mackay dave mackayboats com www mackayboats com North America Pitch Pole Skiff Products Inc 18 Place Decary Dorval QC H9S 3J8 P 1 514 944 1705 Tej Trevor Parekh trevor 49er cam United Kingdom Ovington Boats Ltd Tannners Bank North Shields Tyne amp Wear NE30 1JH Great Britain P 44 0 77 19 59 49 49 Chris Turner chris ovington co uk www ovingtonboats co uk Spars WARRANTY WARRANTY Southern Spars will remedy faulty workmanship provided that any claim by the Customer for remedy of workmanship was notified to Southern Spars in writing within 12 months of the delivery date of the mast Southern Spars will if requested to do so use reasonable endeavours to assign to the Customer the benefit of guarantees and warranties given to Southern Spars by third party suppliers or manufacturers The warranties above do not extend to and Southern Spars shall not in any event be liable for any failure or damage arising from fair wear and tear Any claim shall be made directly to the Dealer from whom the rig was purchased Wa
8. a fastener added to spreader Fastener added to top spreader under the track at back Retrofit details below Halyard Hanger Strengthened Extra weld added to halyard cleat hangers to stop breakages Patching added at Lowers An extra layer of carbon patching was added at the D1 to strengthen the mast in this area T bar neck length refined During 2009 a number of T bars cracked To fix this the neck length of the T bar was shortened a little The neck must be only just long enough to allow the swage to line up with the end of the spreader Also please ensure that your rigger uses a roll swage machine and not a pull swage machine Check T bar hook regularly July 10 Testing of Spreader Keyway system COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 Spars June 09 Aug 09 Nov 09 RETROFIT DETAILS EXTRA FASTENER ADDED TO TOP SPREADER The new rigs are experiencing higher loads than the old rigs This is partly due to the new sail plan and also the strength and stiffness of the new carbon mast Sailors are commenting on how much harder they can push the boats and how they are applying higher loads We are getting some good feedback from the rigs and would like to alert sailors to the following issues Drill 4mm hole at centreline of Countersink hole do not drill too deep Spreader and centre of track 1 Top spreader twisting A number of crews have commented that the
9. der Fit the lowers in the bottom section ATTACHING STAYS Before putting the rig up perform a final check confirm that all fittings are Please note The T bars on the forestay and main shrounds need to attached correctly nuts are tightened and that all clevis pins and sharp be long neck T Bar hooks These will then sit correctly and allow pieces are taped the swages to line up correctly with the wire Fit one end of one of the uppers stays with eyes on both ends onto the uppers bolt making sure there is a washer on each side between the mast and upper stays Then bolt through mast ensuring the gennaker halyard is in front of the pin and the main halyard is behind the pin Fit the second upper stay and tighten uppers bolt Remove the clevis pins and retainer stay plates from the outer ends of the top spreaders Place stay into hook then refit stay retainer back into spreader with the hook facing forwards Next fit the shrouds by inserting the T bar end of the stay in the mast This should be inserted just beneath the NOTE Under Class rules the mast sections and spreaders must be able top spreader to come apart for measurement purposes If you choose to glue your spreaders to the mast section then ensure you use a good release agent and apply it well so the spreaders and mast are not damaged when you are required to break them apart for measurement COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOB
10. e South Africa Sri Lanka and headquarters in Auckland New Zealand It is supported by the North Marine Group and shares the resources of that group of companies For more information www southernspars com Spars
11. e not twisted and are running freely JOINING THE MAST To join the mast together slide the top spreader spreader with Dynex loop on over the join at the top of the midsection Fit locating screw Slide bottom spreader over join at the bottom of the midsection Fit locating screws Now align the spreaders with the mastbase making sure that the sail track is aligned Once aligned tightly fasten locating screws When attaching the spreaders and joining the mast sections make sure that the joins butt up against each other The angled cuts are done at exactly 22 596 If you are to fit a replacement to your rig and it doesn t accurately align lightly sand the join of the mast and use a small rats tail file in the fastening hole so the screw doesnt pull the mast out of alignment Spars ATTACHING TRAPEZE LINES When attaching the trapeze lines to the Dynex loops at the top Remove the clevis pins and retainer stay plates from the outer ends of the spreader make sure both trapeze lines go through both loops bottom spreaders Place stay into hook then refit stay retainer back into Do not attach one trapeze line to one loop then the other trapeze spreader with the hook facing forwards Wrap tape around the spreader line to the other loop both trapeze lines need to be through both end Rubber splicing tape is best loops Fit the forestay to the mast by inserting the forestay on the front of the mast just above the top sprea
12. end weight and CG Bend is determined by the tube stiffness spreader angle and spreader stiffness while weight and CG are controlled through strict quality control of materials It was also important to ensure the rig retained its ability to perform through the full wind range while targeting an ideal crew weight of 155 160kg Before building the first prototype rig many hours were spent running finite element Studies of the mast sail combination to ensure the rig performed properly throughout the full wind range COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 Theoretical rig setup dock tune was established and the boat was run through a range of conditions using the software to simulate real sailing loads to output the deformed sailing shapes of the mast and sail The mast stiffness and sail design was changed many times and fine tuned using the software before it was made and sent sailing Independent on the water testing was conducted by Julian Bethwaite and his team using the first prototype rig in conditions ranging from 5 30 knots along with a range of crew weights The rig has been developed as a 3 piece mast The longest section is less than 4m so it is able to be easily freighted around the world Both sets of spreaders are identical and interchangeable The spreaders slide over the tube joining spigots between the mast tubes and are separate parts This allows
13. hat we can use to develop a more detailed guide to onedesign southernspars com 49er USERS MANUAL 2010 RIG TENSION The mast is stiffer overall so the shroud tensions have changed The top of the mast is a lot stiffer so the uppers require more tension to set the head at the right depth The head needs to be flatter than before for the head to work so it may take some time to get used to looking at the flatter top Don t worry about the tension of the main shrouds As long as the forestay is at the right tension and the uppers and lowers have the main set up at the right depth and behaving right through the wind range then the shrouds are at the right tension This style of rig is probably a little more sensitive to lowers tension than the old rig and fine tuning them will make big differences to the balance through the wind range LIGHT MEDIUM HEAVY FORESTAY 25 28 30 LOWERS D1 20 20 20 SHROUDS V1 D2 28 32 36 UPPERS V2 D3 20 20 18 COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE UPDATES NB Over time there will be updates in some of the fittings used and other detail changes to the rig These will originate from sailors feedback and new ideas Any changes are agreed to by Julian Bethwaite and these changes will not affect the performance of the rigs The tube bend and weight will remain within the agreed tolerances and will comply with the class rules UPDATE DETAILS EXPLANATION Top joining not gl
14. retch slightly after sailing therefore it is important to re inspect your tuning each day for the first 2 3 sessions after sailing with the new rigging Tape any clevis pins or sharp edges to prevent tearing of the spinnaker WEEKLY INSPECTIONS All halyards taping etc should be checked on a weekly basis MONTHLY INSPECTIONS Check to see that all sheaves are free turning and well lubricated Check for wear on stays and spreaders BI ANNUAL INSPECTION amp RE RIGGING INSPECTION Check all fittings for wear Check mast tubes and all composite parts for any damage caused during sailing Spars QUICK SET UP GUIDE 1 Fit soreaders to midsection Slide top spreader with dynex loops over join at top of midsection Slide bottom spreader over bottom join 2 Fit main halyard and gennaker halyard going either side of upper bolt 3 Fit jib halyard 4 Join mast sections together COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 Fit forestay and lowers Tie trapeze lines through both Thread halyards through mast base Attach mastbase Align spreaders with mast base and ensure sail track is aligned Tightly fasten screws Fit upper stays to bolt and run through top spreader Fit shrouds just below top spreader and run through bottom spreader ends of Dynex loop SouthernSpars SET UP TIPS USEFUL TOOLS WHEN ASSEMBLING THE MAST
15. rranty claims must be made on the correct form before any work is undertaken on the part concerned COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 ABOUT SOUTHERN SPARS Southern Spars has established its place as a world leader in the design construction installation and servicing of carbon fibre masts booms composite components and rigging Its rigs power a wide range of yachts from one design class yachts to grand prix racing yachts cruising yachts and superyachts Innovation quality and an insatiable desire to produce what the customer requires runs through the company s culture These qualities have contributed to producing product for numerous race victories including the Volvo Ocean Race Vendee Globe America s Cup Sydney Hobart plus supplying rigs to some of the hottest one design classes like the Olympic 49er Elliott 6 Melges 20 24 amp 32 amp the Farr 30 amp 40 The same design expertise manufacturing methods materials and components utilised on these racing rigs are applied to every rig built by Southern Southern Spars also operates a rig service network and is manufacturing composite rigging The specialist rig service business Rig Pro has service centres worldwide The Composite Rigging division manufactures custom lightweight rigging products including EC6 carbon rigging Aramid rigging and the Luff Rope Southern Spars has centres in the USA Europ
16. simple assembly and ensures that the spreaders can be easily transported separately and protected from damage eSouthern Spars have developed a unique system where the spreaders automatically line up when the mast sections are fitted together main and spinnaker halyard sheaves are incorporated into the masthead fitting ePurchase systems for the Main and Jib halyards are now attached to the mast base to give more travel and easier access for adjustment eThe main halyard has a 2 1 purchase at the head plus a 2 1 adjustment at the base Spars WASHDOWN Ensure the spar is washed down regularly and all salt has been removed This will help prevent corrosion of parts The mast should be thoroughly washed down once a month inside and out to keep it in top condition PAINT SCRATCHES Paint scratches should be touched up to avoid bare tube being exposed to the elements Any 2 part polyurethane paint system can be used to touch up the Spars TRAVEL When shipping your mast or travelling by road it is important to package it well using covers which are available from Southern Spars through your dealers Ensure that rigging is removed to prevent the stays from wearing or banging against the mast It is recommended a full inspection is performed when re rigging the mast COMPOSITE SPARS COMPOSITE RIGGING COMPONENTS GLOBAL SERVICE 49er USERS MANUAL 2010 RIG INSPECTIONS New Stays will st
17. ued into middle The first batch of masts had the sleeve glued into the top section This put all of the shroud loads onto the sleeve section and glue joint The new solution transfers the loads to the mast tube Some early rigs experienced damage on the ends of the tubes after hard sailing An additional internal sleeve was DATE Nov 08 Dec 08 Join area strengthened added at each join to increase the bearing surface area at the end of each tube Spinnaker halyard sheaves changed Harken sheaves were swapped for Allen SS ball bearing sheaves Gooseneck amp Vang pin detail changed Larger washers were added above and below the gooseneck and vang toggles Please check your washers Vang bracket clevis pin was replaced with a bolt Jib Sheavebox changed Jib halyard sheave box changed from internal fitting to simple Harken drop in box Stopper added to top of Sail track A slug was added to top of track to match cut back in boltrope This will stop excessive damage to carbon masthead by the hayard shackle Gooseneck amp Vang Toggles Strengthened Gooseneck and vang toggles changed to a new stronger Riley toggle Spinnaker Halyard deflector changed The old deflectors were bending upwards from halyard loads when hoisting The new deflector was designed to be retrofitted into the same holes and to stay in place under these loads Vang Strop added as standard part Vang take off strop has been added as standard part to mast Retrofit details below Extr
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