In-Mast Furling Repair - Fixing the Extruded Aluminium Tubing / Foil on an Amel Sailboat 

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This one will be familiar to most Amel Super Maramu owners - it's the bolt that attaches the base of the main mast foil to the in-mast furling system.
Over time the bolt that attaches the foil to the in-mast furler mechanism wears an elongated hole in the foil itself and sometimes actually cracks the foil and breaks the base off. So this maintenance video shows how I repair that fault and reinforce that area.
About a year ago you might have seen that when we're in denier on the east coast of Spain I had a problem with the manual fuller. At the time I noticed some hole 'creep' in the foil where the the bolt goes through. Over time the bolt had been grinding itself out a little elongated hole. So I thought I'd check it again a year later and the polyester filler that i put in had all cracked away. I kind of suspected that would happen because i had no actual binder at the time and the temporary fix was just too brittle.
So I didn't think an epoxy repair by itself would actually cut it anymore so what I did was drop the foil a little and cut off the end with an angle grinder and re-drilled the hole. But this time I put in an aluminium sleeve and filled around it with a polyester resin containing fibreglass pieces. Then i fitted the foil retainer back onto the manual furler.
The furler has four delrin spacers that fit between the outside of the mast and the actual manual furler itself, so the bolts have to fit through the mast through the spacers and into the manual furler.
This is a much easier job with two people because somebody can hold the furlers in place while somebody puts the little delrin bushes in bolts it all in place.
If you want to see how the whole thing fits together and works then check out the manual furler repair blog that i did before.
If you're a professional, expert or even an old salty sea dog with some good advice on in-mast furler repairs on sailboats, then please leave any constructive criticism, insight and advice in the comments below the videos.
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