 LUFF
STRAIGHTENING INSTRUCTIONS
If you receive your Flexible Furler luff via UPS, the first
part of the assembly process is to straighten the luff. (You'll
notice a bright colored instruction sheet on the outside of your
luff box.) This should be done within a day or two of receipt. Straightening
takes three people for the FF1 and FF2 and four people for the FF4
and FF6. Strength is not required, just the number of people in
order to control the long coiled extrusion.
1. Carefully remove the tape holding the luff in
a coil. (See diagram on instruction sheet.)
2. Then, pull the luff out straight, with a person
at each end of the luff and the other person(s) along the middle
of it. Make sure everyone's holding the luff at a constant height
off the ground, and with the grooves up and down.
3. Next, bend the luff until it is in one big hoop
in the direction opposite the natural bend.
4. Tape the upper end to the lower end where the
natural curve starts, usually a few inches above the sail feed slot.
5. Let the luff lie on the ground in a circle.
Leave it there for at least three hours, until the luff remains
straight after releasing the tape. The warmer the temperature, the
quicker it will come straight. The hard part is over. Please note,
if the straightening process seems ominous, CDI can ship the luff
in a 6' hoop or via truck.
ASSEMBLY INSTRUCTIONS
1. Measure the length of the forestay.
Reduce that length by the amount shown in the manual and cut the
luff to the resultant length.
2. Pass the internal halyard through the halyard
top fitting. Slip the halyard top fitting over the upper end of
the extrusion.
3. Slide the halyard top fitting/extrusion over
the headstay.
4. Pass the spool over the lower end of the luff
extrusion.
5. Assemble the cup, bearing and antirotation strap
over the lower end of the turnbuckle using the two screws provided.
6. Reassemble the turnbuckle, attach to chainplate
and slide drum into cup and over the bearing.
7. Pass the furling line into the cup and up through
the hole in the upper flange of the drum. Tie an overhand knot to
secure.
8. Lead furling line aft, set the sail and go sailing.
Remember, the installation manual has more complete instructions
including pictures of parts to make installation clearer. Assembly
should take no more than two hours after straightening the luff.
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Assembling
a Flexible Furler is relatively simple and can usually be done by
anyone with a #2 Phillips head screwdriver, a hacksaw and a pair
of vice-grips. It can be done with the mast up or down, and, after
the luff extrusion is straight, can be done by one person (though
it is nice to have a helper to read the instructions while you do
the work). 
