HALYARD EXITS, CLEATS, CLUTCHES, WINCH PADS, HANDLE POCKET

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1 HALYARD EXITS, CLEATS, CLUTCHES, WINCH PADS, HANDLE POCKET 1(6) General CNC-milled masts Cut out using templates Cut out without using templates Assembly Assembly clutch spinnlock ZS/1214 Check point General This instruction describes how to locate and fit slots, cleats, winch pads, rope clutches and handle pockets on mast sections C156-C365 and F156-F406. On F-sections the access and grease holes should also be cut out at this stage. See PHB For reference see MB M 1530:1 MB M 1630 MB M 1660 MB M 1690 P (Layouts, conventional, furling) (Winch pad) (Winch, handle, pocket) (Cleat) C-sections PS drawing F-section PS drawing C 156 PS 584, 583, 534 F 176 PS 543 C 175 PS 585, 586, 535 F 194 PS 544 C 193 PS 587, 588, 536 F 212 PS 545 C 211 PS 537 F 228 PS 546 C 227 PS 538 F 246 PS 547 C 246 PS 539 F 265 PS 548 C 265 PS 540 F 286 PS 549 C 286 PS 541 F 305 PS 550 C 304 PS 542 F324 PS 666 C321 PS 695 F370 PS 693 C365 PS 696 F406 Adapted to mast Table 1. CNC-milled masts 1. Turn the mast with B-line facing up. 2. Clean the mast from oil and metal chips. 3. Grind the access holes on F-sections. M 4. Grind the Ø39,1 on F-sections. C 5. Tap the holes for fastening clutches. If M8; enlarge holes to Ø6,5 before tapping. (see table 5, page 4 ) 6. If the mast is equipped with winch pad(s) and winch handle pocket(s), use them as templates for drilling. Mark the location acc. to PS-drawing or mast specification. Reference hole for winch pads: upper aft hole. Reference hole for handle pocket: upper hole. 7. Turn the mast 180 and repeat steps 1-6

2 2(6) 8. For attachment of fittings see section Assembly. Cut-out using templates 1. Find the right template for the mast being built, see table Turn the mast with the B-line facing up. 3. On keel stepped masts, mark the height of top of mast coat. 4. Position the template aligned with end of extrusion (for keel stepped masts; aligned with mast coat height mark). If double templates; place the upper template against the lower. 5. Drill holes for all functions specified in the mast specification. 6. Remove template(s) and enlarge holes acc. to table 3, 4 and Draw tangent straight lines to mark for slot fitting cut-out. 8. Cut along the inside of the lines with a tenon saw. The cut-outs should not be wider than the diameter of the holes. 9. Grind the edges on the inside of the slot fitting cut-outs. C 10. Tap holes for clutches and cleats. (See table 4 and 5) 11. Remove burrs and degrease the mast surface before mounting fittings. 12. For attachment of fittings see section Assembly. 13. Turn the mast 180 and repeat steps 1-12 Section Cleat Port Cleat Stb Slot Port Slot Stb C 156 C 306 C 305 C 308 C307 C 175 C 406 C 405 C 408 C 407 C 193 C 506 C 505 C 508 C 507 C 211 C 606 C 605 C 608 C 607 C 227 C 706 C 705 C 708 C 707 C 246 C 806 C 805 C 808 C 807 C 265 C 906 C 905 C 908 C 907 C 286 C 1006 C 1005 C 1008 C 1007 C 304 C 1106 C 1105 C 1108 C 1107 C 321 C 365 F 176 F 194 F 212 F 606 F 605 F 608 F 607 F 228 F 706 F 705 F 708 F 709 F 246 F 806 F 805 F 808 F 807 F 265 F 906 F 905 F 908 F 907 F 286 F 305 F 324 F 370 F 406 Table 2

3 3(6) Cut-out without using templates 1. Find the relevant PS drawing acc. to table If the mast is keel stepped, mark the height of the mast coat upper edge and use this mark as base line. If the mast is deck stepped, end of extrusion is to be used as base line. 3. Turn the mast with the B-line up and attach a measure tape at the end of the mast section or at the mast coat upper edge mark. Fasten the measure tape about four metres up the mast. 4. Mark the height s for all specified slots fittings, cleats, clutches, winch pads, and handle pocket(s). Slots and cleats are marked with a number in the mast specification which refers to the PS-drawing. 5. When the height s are marked, mark the side s measured from B-line. 6. Draw a line parallel to the B-line through each mark. 7. Mark all remaining holes acc to table 2, 3 & Use the winch pad as template and mark all holes with a pencil. Reference: upper aft hole. 9. Use the winch handle pocket as a template and mark the holes with a pencil. Reference: upper hole. 10. Pre-drill with a Ø4,9 mm drill bit in all marks. 11. Enlarge the holes acc. to table 3 (slots), table 4 (cleats), table 5 (clutches). Winch pads and handle pockets: Ø6,5 mm. 12. Draw tangent straight lines to mark for slot fitting cut-out. 13. Cut along the inside of the lines with a tenon saw. The cut-outs should not be wider than the diameter of the hole. 14. Grind the edges on the inside of the slot fitting cut-outs. C 15. Tap holes for clutches and cleats, when stated. (See table 4 and 5) 16. Remove burrs and degrease the mast surface before adding fittings. 17. For attachment of fittings see section Assembly. 18. Turn the mast 180 and repeat steps 1-17.

4 4(6) Ø A Slots Part No Size A (hole saw) B Medium Small Large X-large B Table 3. Cleats Part No Size ØA B mm 4,9 mm 20 Comp mm 6,5 mm 40 Comp mm 6,5 mm 45 Comp mm 6,5 mm mm 6,5 mm 27x mm 4,9 mm M6 33 (Polished) mm (Polished) 6,5 mm M8 50 ØA B ØA Ø Table 4. Clutches (Stopper) & jammers Part No Size ØA (screw) B Lew. Ø6-Ø8 Ø4,9 mm M6? Lew. Sing. Ø8-Ø10 Ø6,5 mm M Lew. Sing. Ø10-Ø12 Ø6,5 mm M Lew. Sing. Ø12-Ø-14 Ø6,5 mm M Lew. Sing. Ø14-Ø16 Ø6,5 mm M Spinlock. XCS0814 Ø6,5 mm M Spinlock. XTS0814 Ø6,5 mm M Spinlock. XX0812S Ø4,9 mm M Spinlock. XAS0612/1 Ø4,9 mm M Spinlock ZS 1214 See Haly. Lock 30x150 (WIRE 8 mm Ø6,5 mm M8 122 Table 5. ØA B

5(6) Assembly 1. If necessary, compress the slot fitting hook, as shown in pic. 1, using a pair of pliers, to achieve a tight fit around the mast wall. See pic 5. 2.

3. Drill Ø4,9 through the slot fitting hole while holding it firmly pushed up. Fasten with rivet. 4.

If function labels are specified, clean mast with alcohol aft of the slot fittings first and place the function labels parallel to the slot fittings as shown in pic 2. 7.

$On fractional masts, wash with alcohol and place the jib halyard over-tensioning label on the same side and at the same height as the jib halyard slot fitting or stopper,$

5 5(6) Assembly 1. If necessary, compress the slot fitting hook, as shown in pic. 1, using a pair of pliers, to achieve a tight fit around the mast wall. See pic Fit the slot fittings into the slots. Check that the fittings are mounted the right way up, and push/knock upwards so that the slot fitting upper end is fixed. See pic Drill Ø4,9 through the slot fitting hole while holding it firmly pushed up. Fasten with rivet. 4. Fasten all cleats, winch pads, and handle pocket(s) with fasteners acc. to mast spec. Use rivet pistol with long nozzle to rivet cleats. 5. Punch out all mandrel heads. 6. If function labels are specified, clean mast with alcohol aft of the slot fittings first and place the function labels parallel to the slot fittings as shown in pic Wash with alcohol and place the Seldén logo 100 mm above the uppermost slot fitting, see pic 2. (One Seldén logo on each side at the same level.) 8. Wash with alcohol and place the cable marking label ~50 mm above end of extrusion on the starboard side, see pic On fractional masts, wash with alcohol and place the jib halyard over-tensioning label on the same side and at the same height as the jib halyard slot fitting or stopper, see pic Turn the mast 180 and repeat steps Pic 1 Pic 3 Aft Fwd SLOT FITTING Pic PIC 55. CONTACT POINT Function label ~ 100 Pic 4 Pic 2

6(6) Assembly Clutch spinlock ZS/1214 For reference see 508-358 1. Decide height, side measure for the clutch and make a mark. 2. Draw a line parallel to the B-line through the mark. 3.

Drill Ø 4,9 mm in the marks and tap for M6. 6. Mount the clutch Spinlock ZS/1214 on the mounting plate (508-358) by using four screws MFT 8x20 from under side mounting plate and into the clutch. 7.

6 6(6) Assembly Clutch spinlock ZS/1214 For reference see Decide height, side measure for the clutch and make a mark. 2. Draw a line parallel to the B-line through the mark. 3. Fit the mounting plate with the centre mark on the line with the front pointing to the winch, see pic Mark the 8 holes for MFT 6x20 screws on the mast. 5. Drill Ø 4,9 mm in the marks and tap for M6. 6. Mount the clutch Spinlock ZS/1214 on the mounting plate ( ) by using four screws MFT 8x20 from under side mounting plate and into the clutch. 7. Apply Loctite 639 on the screw threads. 8. Fasten spinlock ZS/1214 with mounting plate on the mast with 8 M6x20 screws, see pic Use Schneidmittel or similar on the screw threads. Pic 4. Pic 5. Check points Check that insulator is fitted between winch pad and winch. Check that access and grease holes are cut out.

SPINNAKER POLE TRACK AND GUIDE CONSOLE

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