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Adventures In Maintenance, Part 1

My friends Melissa and Guy Stevens were somewhere in the middle of the Pacific Ocean, in their sloop Pneuma, when they discovered that they couldn't lower their Genoa. They wanted to get it down for a bit of repair, but the halyard swivel on their Profurl furler kept hitting an obstruction, and wouldn't slide down the foil.

This didn't make for an emergency, because conditions were about as calm and unthreatening as they could possibly be, with absolutely no wind, and a sea so calm and flat that it scarcely seemed a sea at all. Ordinarily, going aloft anywhere but in a marina is something to be avoided, at least in small craft, but in this case it made perfect sense for Guy to get his climbing harness on, and get up there to see what the problem was.

The furler was a Profurl, and it quickly became evident that the problem was a fairly common one, specific to this brand. Every furler brand has its quirks, and one of Profurl's is that the foil sections are held together by machine screws that are coated, at the factory, with a threadlocker (Loctite is the best know type of threadlocker).

This threadlocker is dry when you get the furler kit, and is activated once you screw it into the foils. Or that's the way it is supposed to work; there seems to be more threadlocker on some kits' screws than others. And maybe sometimes the formulation isn't quite right, so it won't stick as well as it should. In any event, while the screws in most Profurls stay obediently in place, you occasionally hear about situations like this one, where the sail can't be lowered because, in the course of sailing, the foil has rattled and twisted, the screws have backed out, and their heads are now projecting past the surface. Some sailors, either because it's an emergency or because it's just how they do things, will force the sail down, hauling mightily on the luff of the sail. This can work, if the crewmembers are heavy and/or panicked enough, as the halyard swivel has a plastic inner lining. So with sufficient force you can make the screw head(s) carve channels up the inside of the lining, which of course damages said lining, and does nothing to address the root cause of the problem, so the screws can continue to work their way out, making it even harder to raise or lower the sail next time, as well as gouging even deeper channels.

Of course, since most roller-furler jibs get left on the stay for years at a time, it sometimes happens that, especially on those long voyaging tacks, the screws can fall completely out of the foil, with no one the wiser, which means that the foil sections are no longer held together, which means that, depending on the quality of the installation, they can drift apart to varying degrees. The most common consequence of this is that a bight of the sail's luff herniates out between sections, making it impossible to lower the sail. There are other possible consequences, but thinking about them just depresses me, so I'll leave them to your imagination. The short form is that you don't want those screws to back out, which is why Harken, for instance has you pretty much bathe all parts in red Loctite, and why Schaefer, to take another example, puts their units together with stainless rivets.

Oh, and a perverse alternative Profurl scenario involves the fact that thread-locking adhesives also function, to a certain extent, to isolate dissimilar metals. So if the insufficiently-coated screws don't back out, that just means they will stay in place, becoming one with the adjacent aluminum through the wonders of galvanic action, until not only will they not back out, but you'll be tempted to use explosive devices to budge them, should you ever need to disassemble the foil for repair. What typically happens, if explosives aren't handy, is that first you'll strip out a couple of screw heads trying to remove them, then progress through penetrating oil, impact driver, easy-outs, heat, cursing, and utter despair, at which point you will pause to regroup, then attack anew with a sharp drill bit. This will remove the screw, but will also almost certainly chowder the threads on the (expensive, impossible-to-find-in-the-remote-port-you-are-doing-this-repair-in) aluminum bearing holder that the screws are tapped into, and very likely also chowder the holes in the foil itself. In addition, you are liable to discover, once you slide the ruined bearing holder out of the foil, that though the heat you applied earlier might not have loosened the screws, it did manage to turn the equally hard-to-find internal plastic bearings to slag.

Well, Melissa and Guy are not the sort of people to let teensy screws get away with things like the above, which is why Guy was up there on that flat calm day. He first detached the head of the sail from the swivel, so that Melissa could gather the sail in on deck. Then he got to work, with a little baggy of spare teensy screws (they are easy to drop, so bring spares), a screwdriver, and some Loctite. He was up on two halyards (a primary and a safety), plus he had an approximately 2' tether looped around the stay to hold him close enough to the foil to do the work. He made his way down, section by section, removing screws, coating them with Loctite, and putting them back in.

All went well until he was about halfway down, at which point Melissa called up to him.

"Hey Guy!", she said.

"Yeah?", replied Guy.

"Swell!", said Melissa, and pointed off to one side.

Guy looked, and saw the glassy, otherwise utterly flat and featureless surface of the ocean broken by a single, large, rapidly moving swell. It was coming from directly abeam, of course, and there was no time to do anything but hold on. As the swell reached Pneuma, a series of intimately linked, harmonic mathematical elements were put into action. The speed, height, and steepness of the swell, Guy's mass, his position relative to the boat's axis of rotation and center of gravity, the length of exposed halyard, the boats' lateral roll period, and the length of the tether, all came into perfect alignment, such that as the boat rocked, it swung Guy forcefully, unstoppably around the stay. Fast. Guy was indeed holding on, but the foil he was holding onto had been carefully engineered to be able to rotated freely under load. Because the stay was angled, it meant that he was swung forward and up, with an apogee in front of the stay, and higher than the starting point. Which meant that there was now an opportunity for gravity to accelerate the second half of the rotation. As an engineer I know put it, Guy "achieved resonance." Aided by the continued, wonderfully complementary continuing gyration of the boat, he was swung around again. And again. Faster and faster he traveled, and as he did, the halyards spiraled around the foil, shortening as they went, until there was no slack left, and Guy came to a very abrupt stop.

At this point, as often happens in times of stress, he was able to be aware of several things at once; the feel of the foil bashing into him, sun on his face, the color of the sky, and of course the sound of Melissa falling down laughing at the sight of him pulling a stunt worthy of Buster Keaton. But in almost the same instant he was also aware that the boat's ongoing motion, perhaps combined with the elastic effect of the halyards, was causing him to unwind, about as forcefully as he had wound. Again, all the requisite inertial and geometric properties were in utter accord, and he orbited the stay until he was back where he started, and then continued to wind up in the other direction, once again fetching up rather abruptly. This went on several more times, we're not sure how many, as Guy was kind of occupied with the whole acrobatic thing, and Melissa was pounding one hand on the deck and laughing so hard she was having trouble breathing, let alone counting.

Eventually, long after the swell had gone by, the boat stopped rocking, and Guy stopped spinning. Melissa kept laughing, but she was able to tend him on the halyards as, bruised but unbowed, he finished the job.

Got a Profurl? Really good furlers. Fine furlers, very reliable. But you might want to check those screws.

Fair leads,
Brion Toss