DIY Roller Furler

A roller furler is a vertical shaft assembly that wraps or furls a sail around itself. The shaft or spindle of the furler rotates about a smaller-diameter cylinder, permitting the speed of the unfurling operation to be determined by the wind. A roller furler is typically positioned before the mainsail and is used to furl jibs and head sails. Although roller furlers can be mechanized, they need not be powered. Constructing a roller furler from heavy-gauge PVC pipe and a heavy cord allows the jib or other sail to be quickly unfurled by pulling the cord as the wind takes it.

Things You'll Need

  • Tape measure
  • Permanent marker
  • 3-inch schedule 80 PVC pipe
  • Reciprocating saw
  • Steel file
  • PVC adhesive
  • 3 1/2-inch circular steel mounting plate
  • 3 1/2-inch schedule 80 PVC pipe
  • 4-inch schedule 80 PVC pipe
  • 3 1/2-by-4-inch plastic reel
  • 3-inch PVC pipe
  • 3-inch PVC T-connection fitting
  • 3-inch PVC pipe end cap
  • 1-inch heavy O-rings
  • Power drill
  • 1/4-by-18-inch double-threaded steel rod
  • 5-inch plastic line reel
  • 1/4-by-1-inch steel mounting plates
  • 2-inch pine dowel
  • 3/8-by-1-inch machine screw
  • 2-inch PVC pipe
  • 1-inch band clamps
  • 3-inch carabiner hooks
  • 1/4-inch braided nylon cord
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Instructions

    • 1

      Use a tape measure and marker to mark the length of the furler shaft needed on a piece of 3-inch schedule 80 PVC pipe. Note: The length of the furler shaft is the width of the jib or headsail that is being furled. Cut the pipe to length with a reciprocating saw and smooth the edges with a steel file. Apply PVC adhesive to one end of the 3-inch PVC pipe and insert it into the 3-inch mounting plate. Note: The mounting plate will be screwed to the deck afore the mainsail.

    • 2

      Measure and cut the furler spindle (the rotating cylinder that wraps and unwraps the sail) from 3 1/2-inch schedule 80 PVC pipe. Make its length 6 inches shorter than that of the furler shaft. Measure and cut a 3-inch piece of 4-inch standard PVC pipe. Use the reciprocating saw to cut a 1/2-inch gap, running along the length of the piece.

    • 3

      Wet the inside of the cut piece of 4-inch PVC pipe with PVC adhesive and insert it onto the 3 1/2-inch spindle 6 inches from one end. Allow the adhesive to dry for 24 hours. Apply more PVC adhesive to the outer surface of the glued-on piece of cut PVC. Insert a 3 1/2-by-4-inch plastic spool onto the bottom of the spindle pipe and over the wet, glued piece of pipe. This completes the attachment of the spindle reel.

    • 4

      Slide the furler spindle onto the furler shaft, spindle-reel-end first. Measure and cut a length of male-threaded 3-inch schedule 80 PVC pipe as long as the distance from the mainsail to the planned distance to the mounting location of the furler. Apply PVC adhesive to the inside of a 3-inch PVC T-connection fitting and to a 3-inch-wide band around the exterior of the furler shaft 2 to 5 inches below its top end.

    • 5

      Slide the T-connection onto the end of the furler shaft and down onto the wetted band around it. Screw the male-threaded 3-inch pipe into the open flange on the T-connection, leaving the opposite end for connection to the mainsail. Wet the inside cylinder of a 3-inch PVC end-cap fitting and slide it onto the furler shaft.

    • 6

      Drill half-inch holes in line on one side of the furler spindle at 4, 8 and 12 feet from the bottom. Screw 1-inch heavy O-rings into the holes to allow the jib or head sail block (the rigid sail edge) to be snap-locked to the furler spindle. This completes the furler assembly.

    • 7

      Insert the double-threaded steel rod through the hole in a 5-inch plastic line reel. Bend both extensions at an identical right angle and screw 1/4-by-1-inch steel mounting plates onto the threaded ends. This permits the 5-inch reel (the furler reel) to be mounted abaft the spindle reel and perpendicular to it.

    • 8

      Cut a 4-inch piece of 2-inch pinewood doweling and drill a three-eighths-inch hole into the center of one end. Drill a quarter-inch hole in the right-side circular plate on the furler reel, 1 inch from the edge. Drive a three-eighths-inch machine screw through the circular plate and into the dowel. This allows the furler reel to be wound by hand.

    • 9

      Cut small incisions in the trailing edge of the jib or head sail at 4, 8, and 12 feet from its top end. Run 1-inch band clamps through the slits in the sail and around an 8-foot piece of 2-inch PVC pipe. Drill half-inch holes beside these clamps. Snap 3-inch carabiner hooks through the holes in the 2-inch PVC pipe. This completes the jib block.

    • 10

      Mount the roller furler assembly to the deck afore the mainsail of the boat. Attach the mainsail connection at the top of the furler shaft. Note: This varies by mainsail design. Attach 30 feet of quarter-inch nylon cord to the spool in the spindle reel. Attach the other end of the cord to the spool in the furler reel. Spin the furler spindle, collecting all the cord.