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1.Identify all the necessary items. Identify all the items necessary for assembly: • 1 x 85mm bolt. • 1 x 70mm bolt. • Frontend Lever. • Main boom frontend body. • 2 x 1mm boom connector shims. • 2 x 2.5mm boom connector shims. • 2 x plastic O rings spacers. • 1 x mast shim.

2.Remove old one.

2 X 1MM BOOM CONNECTOR SHIMS

2 X 2,5MM BOOM CONNECTOR SHIMS

MAST SHIM

70mm BOLT

85mm BOLT

MAIN BOOM FRONTEND BODY

PLASTIC O RINGS SPACERS

FRONTEND LEVER

Next, take off your old boom head unit.

3.Shim thickness. Determine which shim thickness you will need and install the correct one. The 1mm shim’s will fit a 40mm carbon boom front section. The 2.5mm shims will fit a 36mm boom front section. Set them on with the seams facing the boom tail, and the slanted edge to the inside as shown.

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Maui Sails| Our Experience Your Reward MauiSails Boom Head Assembly Instructions

4.Spread it over. Take the main boom frontend body and spread it over the boom front. It will take some force, but is easy to do.

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6.Squeeze the clamp body. Squeeze the clamp body and work the bolt into the other side of the seam, making sure to go through the plastic O ring spacer. Now tighten the bolt.

5.Put the lever. Put the lever onto the clamp body as shown below with the MauiSails logo up. Put the longest bolt into the hole on the cleat side of the lever. When the bolt is halfway through, place the black plastic washer/spacer in the seam of the main body as shown below.

It takes a 5mm hex wrench to tighten the bolts. This is the same as a 2007 MauiSails batten tensioner wrench, which works perfectly. Fit the second bolt, and don’t forget the spacer on the other side. Tighten the second bolt. Be sure and center the fitting on the boom front and tighten it securely so it won’t move around.

Remember to line up the break in the shim with the break in the boom head.

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Maui Sails| Our Experience Your Reward MauiSails Boom Head Assembly Instructions

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7.Insert the mast shim.

8.Thread a tensioning line.

Insert the mast shim. Use a flat screwdriver to lightly lever the insert into the tabs.

Thread a tensioning line and you are ready to use the new MauiSails boom head.

If you still have some problems or questions don’t hesitate to contact us over www.mauisails.com

Our experience Your reward.

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MauiSails Boom Head Assembly  

MauiSails Boom Head Assembly

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