NONSUCH SPARS Recommended Owner s Maintenance Schedule

Transcription

1 NONSUCH SPARS Recommended Owner s Maintenance Schedule The first Nonsuch masts were designed and produced in 1978 and these prototype spars are standing and functioning today after seven seasons of hard sailing. The concept of the free-standing spar requires a different approach to engineering and design of the mast because fatigue becomes the primary consideration. For this reason, it is very important that no hardware be added or holes drilled into the spar, especially at deck level or for several feet above. The addition of a hole could create a jagged edge and hence a stress riser from which a crack could propagate. If hardware is to be added to the spar or any alterations are to be made to the mast or any of the structural components the factory must be contacted. We cannot be responsible for any damage or loss due to unauthorized alterations. Over the past six years, we have learned that there are some parts of the mast that should be examined on a regular basis, preferably at an annual or even semi-annual interval. For this reason, we do not recommend that a spar be stored standing in the boat over the winter months. We feel that by removing the spar at the end of the season, it can be properly examined for any loose fittings, rivets, or defects that, if noted early, could be easily and successfully repaired. The following mast maintenance suggestions may apply in whole or part, depending on the vintage or model of your Nonsuch. These points for the most part, should be observed as part of an annual check list and on a semi-annual basis for boats which sail the year round. 1. Mast Step: The casting is securely fastened and bedded into fibreglass with stainless steel lag bolts. These bolts should be checked for tightness once a year with a good socket wrench. If any of these bolts are loose, tighten them. If one has been stripped or lost its holding power, back it out, bed it in epoxy, even five minute epoxy, and re-torque it. If several of these bolts are stripped, drill new holes between the old ones and insert additional lag bolts. The required size is 3/8 x 2 length. Contact the factory if you are unable to find these bolts. When stepping the spar each season, be sure that the four retaining bolts at the sides of the mast step are backed out so as not to prevent the spar from seating properly in the step. Apply Locktite to these bolts and tighten them against the spar heel to eliminate any movement of the mast within the step. These bolts must be checked twice a season just to be certain that they remain tight. If a loud thumping is heard in the mast compartment, then these retaining bolts are likely loose and the mast is moving in the step. Refer to Figure 1--

2 2. Mast Deck Collar or Partner: On Nonsuch 26s and 30s built prior to the spring of 1984, a pin was fitted through the collar and mast at deck level to prevent the spar from jumping the step. It is important that your dealer be contacted before the spar is re-stepped this season, so that he may install a new tie down system. 3. Mast Collar Wedges: The mast wedges are fabricated of hardwood; either oak and ash, and are designed to fit snugly between the mast and collar casting. These mast wedges should require tapping with a hammer to drive them home so that all wedges fit uniformly and tightly. Damaged wedges should be replaced when re-stepping the spar each year. Loose wedges should be replaced or shimmed to desired tightness. It is important that all wedges fit snugly between mast and collar to assure uniform load transfer to the collar and deck structure. 4. Lower to Upper Spar Section Joint: Over the years, three methods of mechanically fastening the two sections together have been used. Naturally, if these sections were not securely fastened together, the top half could rotate and misalign the sail track. On the earlier Nonsuch 30 masts, the sections were riveted together. This method proved to be not totally satisfactory and the suggested fix would be as described in the third and current method as described below. The next method used on both Nonsuch 26 and 30 through the 1983 model was to use aluminum straps inside the spar as back-up into which several hex-head machine screws were tapped. However, with the constant flexing of the spar, some of these fastenings could loosen even though set into Locktite. The joint fastenings should be checked for tightness every spring at commissioning or semi-annually if the boat is sailed year-round. Any bolts that are loose should be backed out, reset in Locktite, and tightened with a socket wrench. A couple out of dozen or more bolts used to secure the top of the spar will likely loosen, but re-tightening properly will prevent others from loosening. The third and current method of securing the sections is to through-bolt with specially designed aluminum barrel nuts and studs. Nonsuch 22, 26 and 30 are fitted with two of these through-bolts which penetrate the spar diagonally. On Nonsuch 36, three are installed. These fastenings should also be checked annually for looseness and tightened if necessary, the current method is the most unlikely to loosen, but should be checked. Note that all Nonsuch 22 and 36 masts are fastened this way. Early Nonsuch 30 models using the first described method should be up-dated to this method. Contact Hinterhoeller Yachts Parts Sales or your dealer for the necessary parts. Installation requires drilling 5/8 diameter holes. Refer to Figure 2--

3 6. Sail Track and Fastenings: The sail track on Nonsuch 22,26 and 30 is fastened with 3/16 diameter monel rivets. These fastenings should be checked annually and any loose ones replaced. A loose rivet could eventually jam a sail slide and prevent hoisting or lowering the sail. The fastening of the track in the area of the spar section joint is with No. 10 machine screws tapped into the spar wall. Be sure that these fastenings are also tight and add Locktite to any loose screws before retightening. On earlier Nonsuch 26 and 30 models, the spar joint area fastening of the track was also done with rivets. These rivets could work loose because of improper grip in the double wall thickness. We suggest that the loose rivets be replaced and that No. 10, ½ length machine screws be added between the rivets starting six inches below the joint and extending upward for three feet. This will relieve any stress on the rivets in this area. Nonsuch 36 sail track is fastened entirely with machine screws so these should be checked and tightened as described above. As on any type of spar, all fastenings should be checked and tightened or replaced annually to assure that no hardware loosens off or fails. We use Locktite on all tapped fastenings on the spar not only to lock the threads, but also to act as an electrolysis isolator between the stainless and the aluminum spar. While checking the track fastenings, also examine the track itself for any dents, misalignment or burrs and file or clear any obstructions. Run a sail slide-up the track to be sure it will run freely. Lightly lubricate the track with teflon lubricant. 6. Wishbone Topping-Lift System: Because of the load that the topping lift carries, especially when powering with the sail furled, it is important that the topping lift assembly be kept in good working condition. An annual check-up of the entire system is imperative. First check the Nicro press connections at each end of the vinyl coated wire pennant from the masthead. Any sign slippage or wire fatigue at the Nicro press sleeve requires immediate attention. The wire should be cut and re-swaged by a knowledgeable rigger. Look for broken wire strands at the Nicro press sleeve at the masthead where constant flexing could cause wire fatigue and failure. When re-swaging is required, we recommend the use of two swage sleeves. If your topping lift is fitted with an adjustment tackle, carefully check over the blocks, shackles and all rigging pins and cotter pins and replace any damaged or distorted fittings. All threaded shackle pins must be wired to prevent accidental release. The end of the adjustment tackle should not just be secured to the cleat on the boom. It should also be wrapped or cinched around the wishbone tube in case of the remote possibility of the cleat failing. On the 1984 model Nonsuches, a safety jumper is installed between the lower end of the wire pennant and the wishbone casting. If the tackle or shackles did fail the safety would stop the wishbone from falling more than a few inches. For boats not fitted with a safety tackle, we suggest that a piece of 3/8 diameter braid be secured to the Nicro press eye at the end of the wire pennant and to the wishbone end casting. Leave just enough slack to allow for adjustment.

4 When powering in heavy sea conditions, we recommend that the main halyard be attached to the end for the wishbone and secured. The whipping of the mast can put a great strain on the topping lift wire and if any hardware should fail, the boom will not drop. If any topping lift attachment shackles at the wishbone show signs of bending or distortion, replace them immediately. The loading angle may vary and not always align with the shackle. These shackles are designed to take the load, but fatigue can cause eventual failure. Refer to Figure 3-- All of the above suggested checks should be carried out at minimum annual intervals to ensure trouble-free sailing on your Nonsuch. If any questions arise, please contact Hinterhoeller Yachts or your dealer. Replacement parts are available and can be mailed out promptly. If at all possible, contact your dealer first so that he can co-ordinate any repairs or upgrading that may be necessary.

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