Mike,

I too had this problem with my in mast furling system. Several things that I have done have eased the problem, but not caused it to go away, as I still use the winches to get the sail in and out.
1) Thoroughly wash down the furler roller in the mast with fresh water.
2) Tighten the sail as you furl. This helps reduce the doubling up and wedging problem upon unfurling.
3) Replace the BB ball bearings on the out haul track. They tend to get corroded easily thus restricting the outhaul car from sliding easily. You can order these. The old forum has the place, just search under main sail furling problems. I can't remember where I ordered mine. You will get a piece of track that is very nescessary when loading on the boom track.
4) If your outhaul sheet is large, it may be restricted going through the pulleys in the boom. Pehaps replace with smaller size line. Although, this did not seem to make any difference when I did it.
5) Spray dry lube on all moving parts.
6) Fall off the wind while unfurling. Get the sail out some, and you will be suprised how quickly, and easily that thing will come out, provided tha sail is not jambed from a slack furl problem.

Hope this helps some. The old site forum has all this info too, and you can read other's tips there as I did 3 years ago.

Bill

Mike,

Fantastic idea!! I will try this this week when I go check on the boat. Never thought this could be a solution, but sure is logical. I would guess that just a bit of slackening would do the trick so the main remains fairly tight to the mast? Thanks for the update.

Bill

I also find on Sarah Sue that the boom needs to be adjusted a few degrees above horizontal to allow easy furling/unfurling. This gives a pretty crappy leech sail shape to windward, though, remedied by lowering the boom during these times. I must admit, I miss the excellent adjustable Garhaeur boom vang from my C310.

Mike....

I found letting the boom swing out a bit to the port side when putting out the main makes it easier too. If you look, you'll notice that, with the boom straight aft, the main actually pulls out to the left against the right side of the mast, creating friction.

Letting the boom out a bit lets the main come out in a more straight line.

I don't have an in mast furler, however I know that if I release a little tension on my jib hayard, the jib furls and unfurls more easily. Therefore, I would agree releasing the tension on the main halyard would do the same for the main furler.

I have never had an issue with the furling main and Charleston Spar and was wondering if I would eventually have issues given some of the threads on this topic. I have always added tension when furling the main and then when I got back to the dock, I have always released the tension on the halyard (also Genoa). Seeing some of the suggestions above, I now understand why I have not had problems. Releasing tension on the halyard does make sense and if this indeed works to solve the problem, please post an update so we all know that this is really the solution.
John Meyer
Hilbre 2135 on Lake Mead, Las Vegas

[QUOTE=serena;349]I am experiencing problems with my in mast furling system. The main furls fine, but many times I experience difficulty unfurling and resort to using the winch to unfurl the main. I contacted Charleston , manufacturer of the system, and was told that the mainsail quite possibly has stretched causing it to overlap in the mast when furling. This would make the main tighter in the mast. I now use the winch to furl the main slowly as I tail the outhaul and wind the main very tight. This seems to help, but I still need to use a winch at times. Has anyone else experienced this?
Mike
Serena, 2137[/QUOTE]

I have had the same problem with my Mk II. I tried everything - lubing it, replacing the car... nothing helped. The other day I removed it and found the problem: The inhaul line had swollen (probably from having absorbed salt) and rubbed against the housing. This furler, by the way, is made by USSpars, not Charleston, but maybe it's the same problem.

While reading the above thread I was surprised learn that so many had resorted to the use of a winch to operate their furling systems on what seems like it may have been a regular basis.

The furling system is designed to operate without mechanical power assistance in most reasonable wind conditions, provided it is properly rigged, maintained and lubricated and I thought it worthy of mention that winch power should really only be used with great care, and unless in an emergency situation, only for the winch purposes intended in their design and installation. Because of the enormous power involved, inappropriate use of winches will very often lead to breakages in both standing and/or running rigging and not necessarily at the time the winch is being used.

Over tensioning of the main halyard, whether in mast main furling is involved or not, on all sailboats, is in my experience, the most common mal adjustment in mainsail control/trim. It may not be one of the more critical adjustments as regards boat speed and can therefore easily go unnoticed by all but the most critical eye. So it would not be surprising to find these sails have been hoisted initially and left over tensioned on many boats leading to this problem.

I am very disappointed in what has been reported as the official explanation of the problem by Charleston, as this sail stretching, while possible in extreme cases, is probably quite unlikely, and if so many boaters have been experiencing these furler problems, perhaps they should have investigated a little further.

My in mast furling has never been problematic, but I do sail most of the time with minimal tension on the main and where weather conditions have dictated the halyard should be hardened, I would always release any tension before furling the sail. It is good seamanship to remove all tension from rigging when not sailing. In my early life, I was once told to "be kind to the rigging and it will be kind to you!"