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Old 27-03-2024, 17:04   #1
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Stuck joining sleeve on furlex 100s

Hi All,

I have been trying to disassembly my 100S furlex for too many weeks now to replace a broken tack ring. The forestay is off the boat, and I have followed the manual to remove the entire lower bearing assembly, however I get stuck on the step where I am supposed to grasp the Joining Sleeve with pliers (now exposed from removing the prefeeder) and tap it upward with a hammer into the luff extusion above, freeing up the spring in the lower bearing assembly.

The joining sleeve appears to be loose in the extrusion, but every time I tap with a hammer, it goes no where and I just rip up the joining sleeve from the teeth in the pliers. I have done everything I can think of, but they joining sleeve just wont move.

Wondering if anyone has had experience with this step and could provide tips. Much obliged.

Jeff
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Old 27-03-2024, 17:24   #2
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Re: Stuck joining sleeve on furlex 100s

I used to have one of those on my Hunter H26.

The directions are confusing. You want to pull the insert out, not push it further up into the extrusion. That's why you're using the pliers rather than just banging on the end of it with a mallet.

If you're trying to pull it out but can't, try shooting some JB-80 up in there if you haven't.
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Old 28-03-2024, 04:51   #3
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Re: Stuck joining sleeve on furlex 100s

Thanks - I don't think you can pull it out, as you can see the joint sleeve is definitely inside both extrusions. Here is the manual...

https://support.seldenmast.com/files.../595-102-E.pdf

check out section 4 and section 17. We're stuck on 17.5 step 4.

The current theory is there are distance tubes within the upper luff extension that is stopping the joint sleeve from moving upward. They must be really stuck though?

We tried McLube but should try a more penetrating lube like WD40 or JB80 (never heard of that actually).

Any other tips or advice is appreciated!
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Old 28-03-2024, 11:12   #4
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Re: Stuck joining sleeve on furlex 100s

ok I see


Use penetrating oil. The McLube will only go where you put it. JB-80 is twice as good, says so right on the can so it must be true. Actually it does perform much better as a penetrating oil than WD-40. There are other good choices but WD-40 isn't one of them. Spray it into the foil any way you can, let it sit, do it again, repeat as often as you can stand it, bang on the wrench some more.


If that fails you can try gentle heat e.g. a heat gun on the outside of the foil.
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Old 28-03-2024, 12:09   #5
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Re: Stuck joining sleeve on furlex 100s

OK - Ill report back after trying the oil.

I did forget to mention I tried heating it up last weekend to no avail.
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Old 26-05-2024, 11:19   #6
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Re: Stuck joining sleeve on furlex 100s

Closing the loop on this...

We couldn't get the furlex apart by the book (manual) so we ended up taking a hacksaw to the connection springs. After cutting those, it fell apart no problem. We were able to source replacement connection springs.

However, putting it back together again has shown what went wrong. Inside each piece of aluminum extrusion there is a plastic 'distance tube' or 'push tube'. The correct sequence of install is important for these furlers, and relies on using these plastic tubes to push the joining sleeves under the connection springs after they are put in place. In our case, we figure the plastic tubes have swollen or jammed after being in place for ~20-30 years...so they will. not. move.

This meant that disassembly was impossible (without a hack saw) and further, we are unable to put it back together, as the plastic tubes are stuck in the assembled position and they do not give the joining sleeves the proper space to slide in under the conenction spings (in the right sequence).

anyway - if you find yourself in the situation, there are some details. We havent gotten the tubes out yet, and might not. If not we will assembly by drilling and tapping some holes to put set screws in. If I can remember, ill post here with the end result.
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Old 29-05-2024, 19:52   #7
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Re: Stuck joining sleeve on furlex 100s

Hopefully the final post on this topic....

After further careful examination, the tubes were indeed so swollen they were flat on the sides pressed up against the inside of the extensions. No way they were moving anywhere.

We decided to tap the holes in the extrusions (M4 screws .7 pitch), which were pre-existing from the connection springs. The easiest, least error prone method, at least in our eyes, was to assembly the whole thing, with the forestay wire inside (threading piece by piece), then drilling and tapping into the extrusion and the joint sleeve (but not the forestay!). We bought zinc plated aluminum set screws to seat in there, replacing the connection springs.

Seemed to have worked. I dont wish this on anyone, but should you find your self in this situation there is a path forward that doesnt require scrapping a whole perfectly good furler!
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