Doyle Sailmakers StackPack Manuale utente

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

StackPack

Installation Manual

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

FORWARD TO STACKPACK MANUAL

by DON STREET

As boats become larger and larger with the aid of modern winches, either hand, electrically

or hydraulically powered, most sail handling problems can be solved. But the one difficult

problem that continually faces all crews is the furling and covering of the mainsail,

especially on boats with a main or mizzen of 400 square feet or over.

There are various methods for stowing large mainsails and mizzens - internal roller reefing

(too expensive), behind the mast roller reefing (too inefficient), zip-furl (you have to rely on

a zipper and my son-in-law, Scott Vogel, bowman on STARS AND STRIPES, says that one

thing he learned while racing on 12 meters is "Don't trust zippers!"), the Dutchman, and

now the StackPack.

We installed the Dutchman system and sailed with it for over 1,000 miles. We have now

sailed roughly 4,000 miles with the StackPack. If you are buying a new mainsail, the

StackPack is the way to go! With the Stack- Pack, one person, or at the most two people,

can stow and cover their main and mizzen, regardless of the size of the sail.

Further, the full length battens in the StackPack are a definite plus. Being an original

doubting Thomas and believing nothing until I have tested it in all weather conditions, I

had serious reservations about the efficiency of full length battens. Now after 4,000 miles

using a fully battened main, I am firmly convinced that fully battened sails are the way to

go - so much so , that we now have a fully battened mizzen!

One of the greatest things about the StackPack is the fact that whenever the sail is down,

the sail cover is on it. It is not a case of having to urge a tired crew to cover the sail to

prevent sunburn. The StackPack is really easy and is done automatically once the sail is

dropped.

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

S T A C K P A C K I N S T A L LA T I O N I N T R O D U C T I O N

The following StackPack instructions have been written with the expectation that the initial

installation will be done under ideal conditions: calm weather and seas, five knots of wind

or less, boat head to wind on a mooring or at the dock. Under these conditions the initial

StackPack installation can be made in less than three hours. If it is not possible to wait for

all of these ideal conditions in your particular case, please remember IT IS VITAL TO HAVE

THE BOAT HEAD TO WIND DURING THE INSTALLATION PROCEDURE.

Once the StackPack unit has been installed correctly, the unit should give efficient service

and long life in any reasonable sailing weather, as long as the "StackPack Tips" and

prudent seamanship rules are observed.

NOTE: The StackPack has been adapted to fit a wide range of boats however, for your

StackPack to function correctly, the slide gate on the mast must allow slides to start

stacking up directly above the tack fitting, i.e., the slide gate must be no more than 3"

above the tack fitting. This insures that the stacked height of the slides will be low enough

to allow the acrylic cover to be zipped closed after the sail has been lowered.

Doyle StackPack is a full battened mainsail, with lazy jacks and an integral sail cover

attached to the sail by a membrane and supported at the cover top by two battens. The

sailmakers at Doyle take great pride in constructing this sail and providing all of the

components necessary to easily and properly install it. When you receive your Doyle

StackPack, please check the package for the following components:

A) Dacron mainsail with attached sail cover of correct color and attached, coiled lazy

jacks.

B) Bundle of six full length battens (labeled): top, uppermid, lower mid, bottom, port

cover, starboard cover.

C) StackPack Installation Kit in small gray bag contains the following:

RCopy of manual

RFour Stainless steel pad eyes

REight stainless 1/2" self-tapping screws

ROne 11/64" drill bit

ROne bottle of lubricant for use on luff slides. This has been supplied to lubricate the mast

track so the hardware runs up and down with minimum friction. The easiest way to

apply to the track is from the bosun's chair. Better yet, apply the lubricant prior to

stepping mast at the beginning of the season.

In addition to the components supplied by Doyle Sailmakers, you will also need the

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

following:

RSharp knife

ROne roll of vinyl rigging tape

RBosun's chair

RScrewdriver with 5/16" slot head

RAn electric drill, cordless power drill preferred

RFelt tip marker

The steps for installing the StackPack should be taken in proper sequence to insure correct

and, hopefully, carefree installation. Please read through the whole procedure first to

familiarize yourself with the overall picture:

(Fig. 1 & lb).

RInstall upper pad eyes on mast. (Fig. 2a)

RInstall lower pad eyes on mast. (Fig. 2b)

RInstall mainsail battens and cover battens. (Fig. 3a,b,c)

RInstall (bend) mainsail on to mast and boom. (Fig. 4a)

RRig lazy jacks. (Fig. 5)

RLead forward cover lines to lower pad eyes. (Fig. 2b)

After completing the above steps, be sure to make a dry run, at the dock or on the

mooring. Lower and stack the sail, and close and zip the StackPack to insure everything is

in proper working order. During this practice session, make any final adjustments and

familiarize yourself with the forward cover.

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

INSTALLING UPPER PAD EYES

Pad eyes are most easily installed at the mast head before the mast is stepped. If this

cannot be done, it is necessary to send someone aloft in a bosun's chair. Upper pad eyes

should be located 45% down from the mast head, on opposite sides of the mast, just

behind the shroud tangs. (See Figure 2a) DO NOT INSTALL PAD EYES ON THE AFT PORTION

OF THE MAST, NEAR THE MAST TRACK. If located on this aft section, the pad eyes will

position the lazy jacks in such a way that they will snag the sail when it is hoisted. Do not

locate pad eyes in any position where the lazy jacks will cross a shroud, a piece of

hardware, or any other equipment.

NOTE: It is always more important to keep pad eyes, lazy jacks, and other StackPack

rigging clear of other gear than to install them in any specifically defined location. Once you

have determined the best location of your pad eyes, hold them against the mast and mark

the holes with a felt tip marker. Drill one hole, tap it, insert screw, and secure pad eye

before drilling second hole. Drill the holes with an 11/64" bit and an electric drill (a portable

drill is really handy here if you are at the top of the mast!) Carefully, tap the holes with the

10 x 24 thread tap and wrench.

HINT: To produce clean threading, do not use complete turns in threading the hole. Turn

the tap clockwise one half turn to cut the thread, then back it very slightly (less than 1/8th

of a turn) counterclockwise to break and to release the cut metal. Approximately six

complete clockwise turns should thread each hole.

Align pad eyes over the threaded hole. Screw the bolts into the mast. Turn the bolts as

hard as possible by hand.

INSTALLING LOWER PAD EYES

To determine the position of lower pad eyes on the mast, (See Figure 2b), measure up from

the gooseneck approximately 15% of the mainsail luff length, i.e., 15% of the distance

between the black bands. The same rules for lateral placement of pad eyes apply to lower

and upper eyes.

Install lower pad eyes using same tapping and threading technique as used for upper pad

eyes.

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

Doyle Sailmakers Inc.

1.800.94.DOYLE

[email protected]

INSTALLING MAINSAIL BATTENS

After installing the pad eyes on the mast, proceed to the mainsail installation. To set the

stage for installing the mainsail, remove the sail from the StackPack bag and lay the sail

along the deck of the boat, inside the shrouds, with the luff of the sail at the mast and the

clew, aft near the companionway.

Now you are ready to insert the battens from luff to leech in their respective pockets. There

are four sail battens and two cover battens. Each batten is custom cut to fit exactly and

snugly into its pocket. Each batten is identified with markings to indicate which pocket it

goes into and how it should be inserted. Please note the leech end of the battens are angle

cut to match the leech angle of the sail. After insertion, each batten must be tied into the

pocket, as shown in Figure 3a and 3b, and the Velcro closure should be secured. When

inserting the cover battens, note that each cover batten has a line passed through it, as

shown in Figure 3c at the forward end. This line, when the batten is in place, must pass

through a hole in the batten pocket in the acrylic StackPack cover. There is no need for any

other Velcro closure on cover pockets.

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