A-‐SPRIT Carbon Fiber Bowsprit Through Hull Attachment

Trogear Marine Products www.trogear.com [email protected] 866-­‐616-­‐2978 A-­‐SPRIT Carbon Fiber Bowsprit Through Hull Attachment Installation Manual Congratulations on your purchase of the Trogear A-­‐Sprit! Our Bowsprit can be installed on most sailboats. The through hull installation is not a complicated process, but it does require careful measurements. Please read though the instructions first, and if in doubt contact us or your boat rigger with any questions. Keep in mind that these instructions present the basic process. As each boat is designed differently, your boat may require specific installation modifications. Again, please consult your rigger if in any doubt, and you may decide that it is best to have your rigger install the A-­‐Sprit for you. NOTE: If you are not able to install using this method, our deck mounting solution might be right for your boat. See our website or contact us for details. Materials and Tools Required •
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Masking Tape Marker or pencil Tape measure •
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Isopropyl alcohol or acetone Vinyl gloves Paper towels •
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Drill motor Pilot drill bit and 1 inch drill bit Round or rotary file Structural Epoxy –West System Six10 or •
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Sandpaper grid 60 Blue Loctite similar Parts for the Adjustable Bobstay Attachment •
5/16 Dyneema (The bobstay purchase is 2:1. Measurements are specific to each boat) •
U bolt for Bob stay attachment (consult your rigger or sailmaker to determine the working loads for your boat) •
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Thimbles or blocks Bungee cord •
Stop strap © 2015. Trogear AS-­‐30 installation manual. www.trogear.com | update 8-­‐24-­‐2015 1 OVERVIEW The bowsprit is attached to the boat via a transversely mounted Fiberglass tube (hinge tube) with a movable marine grade aluminum shaft connecting the bowsprit ends. The hinge tube is permanently bonded to the hull with structural epoxy such as West System Six10 or equivalent. In some cases, depending of the construction of the hull, the area surrounding the hinge tube could be reinforced. (contact us if in doubt) Due to the high compression forces under load, each hinge tube end should not protrude past the hull more than ¾”. If the hull is narrow, such as on a trimaran, the addition of structural spacers is a viable solution. (Fig. 1: Make sure that there is no obstruction in this area below the deck. Fig 2 shows the hinge tube inserted.) Fig 1: The area below deck is clear Fig 2: The hinge tube inserted INSTALLATION PROCEDURE Determine the Location of the Holes for the Hinge Tube: Note: Keep in mind that the final position of the tube should be as close to the deck as possible. •
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First you want to determine the vertical distance from the deck for the center of the Hinge tube hole. Place a stripe of masking tape below the deck on each side of the bow in the area where the tube will be installed. This protects the paint and is for temporary markings. Fig. 3. Fig 3: Tape below the deck. © 2015. Trogear AS-­‐30 installation manual. www.trogear.com | update 8-­‐24-­‐2015 2 •
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Determine the horizontal distance from the bow tip based on the Hinge tube width of 8”-­‐9”. One method is placing the Bowsprit temporarily in the mount location. With the ends touching the hull, mark the center of the holes using A-­‐sprit attachment holes. Fig. 4 (This is best accomplished with a helper) Both centers of the holes should be symmetrical. Check by comparing the distances using a piece of non-­‐stretching line attached to the headstay. Fig. 5 (Move the hole center locations if necessary) Fig 4: Use the A-­‐Sprit to determine placement. Fig 5: Using non-­‐stretching line attached to the headstay, check that the distances you marked are the same on each side of the boat Drilling Holes for the Hinge Tube: NOTE: You may cover upholstery or other parts inside against debris •
First, drill a pilot hole through the hull on each side. The hole should be horizontal and perpendicular to the boat’s longitudinal axis. Fig. 6 Fig 6: Drill pilot holes first. © 2015. Trogear AS-­‐30 installation manual. www.trogear.com | update 8-­‐24-­‐2015 3 •
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Next, using a 1” step drill, drill the holes for the tube. Fig. 7 Fine-­‐tune the holes with a rotary or round file. For the best results, the gap between the Hinge Tube and opening should be 0.01” Fig. 8 Fig 7: Drill 1” holes •
Fig 8: Fine tune holes with rotary file. You should be able to push the fiberglass hinge tube through the holes. Position the tube so that both ends protrude an equal distance from the hull. Bonding Hinge Tube to the Hull: Note: Use two steps bonding for the best results. •
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Mask area around the holes leaving about ¼ “ for epoxy fillet. Fig. 9 Mask the Hinge Tube ends to prevent the epoxy from entering the tube. Clean area surrounding the drilled holes and Hinge tube ends with alcohol or acetone and lightly sand with 80 grid sandpaper. Blow out the dust and don’t touch. First Step: Mix epoxy and completely coat the drilled holes, working the epoxy into the Fig 9: Mask area around hole surface. After the epoxy cures, trim any excess epoxy from the holes with a round or rotary file. For the best results the gap between the Hinge Tube and opening should be 0.01”. (For boats with cored hulls, to reinforce the area, we recommend removing at least ½” of core and filling it with West System 404 High Density Adhesive Filler or similar.) Second Step: Insert tube and slide it half way to the other side. Coat the protruding tube and the opposite hole fully with epoxy. Next, so that the epoxy fills the gaps, rotate the tube and continue to slide it the other way. Then, position the tube so that both ends protrude an equal distance from the hull. NOTE: There must be no voids or gaps. To seal the area better and create the strongest joint, once the epoxy sets make a fillet inside and outside the tube/hull joint. © 2015. Trogear AS-­‐30 installation manual. www.trogear.com | update 8-­‐24-­‐2015 4 Install a Bobstay U Bolt The Bobstay is attached on one end to the tip of the A Sprit and is routed to a U bolt attached to the bow. The angle of the Bobstay and A Sprit in a horizontal position should be approximately 45 deg. The location of the U bolt is the intersection of the Bobstay and the Bow. Select the U Bolt based on the hull thickness and choose a Marine grade Stainless Steel with Minimum working load based on your sails and intended bowsprit use (Code 0 type sail generates forces on bobstay twice as high as an Asymmetrical Spinnaker) – if Fig 10: U Bolt attached to the bow in doubt, consult your rigger or sail maker. (Most boats should be fine with 5/16” U Bolts) Install the U Bolt following the manufacturer’s instructions. Attaching the A-­‐Sprit: (careful not to drop parts in the water!) This is done best with a helper but with a little skill and a single sailor can do it too. Place the shaft to the one tube end and Place A-­‐Sprit on the boat with holes mating with holes of the Hinge tube. Now push the shaft all the way though and use bolts and washers to secure it in place. (Torque 130 in-­‐lbs) Temporarily secure in place with a line. Fig. 11 Fig 11: Temporarily secure the sprit with a line Rigging the A-­‐Sprit There are many ways to rig the A-­‐Sprit. Permanently fixed A-­‐Sprit: The simplest rigging is when the A Sprit is used in a permanently extended position without the need for adjustment. Use a fixed length Bobstay with one end attached to the U Bolt and the other attached to the tip of the A-­‐Sprit. © 2015. Trogear AS-­‐30 installation manual. www.trogear.com | update 8-­‐24-­‐2015 5 Adjustable A-­‐Sprit: Our bowsprit’s main design feature is the hinged attachment, which allows it to rotate up and down. (possible also if deck mounting) We recommend a 2:1 Bobstay purchase with the control line leading to a clutch in the cockpit. This allows you to take full advantage of our unique design and adjust the sail luff tension or bring the A-­‐Sprit in an upright position (for stowing or changing sails only). NOTE: The a-­‐sprit should be close to a horizontal position when flying the sails. A bungee cord is used hold the A-­‐Sprit in an upright position. A stop strap is needed to prevent the A-­‐Sprit from dropping below a predetermined angle. Use with a Continuous Roller Furler: Another unique feature of our A Sprit is a horizontal groove on the bushing. When the Sail Luff is under tension during furling, the attachment ring will stay in the groove and prevent the rotation of the Furler… just to make your life easier. ☺ Enjoy! Fig 12: A-­‐Sprit shown in upright, stowed position. © 2015. Trogear AS-­‐30 installation manual. www.trogear.com | update 8-­‐24-­‐2015 6