Luger Voyager 30

Installation Instructions
#3023 Mast Raising Lowering System

Before starting installation take the time to have a full and complete understanding of the system.

Read the instructions, study the illustrations and become familiar with all component parts before beginning.

Figure 1 shows the general relationship of all major parts included in the #3023 Mast Raising/Lowering System.  This system consists of two major groups.  First, the lever tube which directs the force of the main sheet system (moved from the cockpit area to the foredeck) in the proper direction to raise and lower the mast. 

The second is the stabilizing system which keeps the mast and lever tube parallel with the centerline of the boat in all positions from lowered to raised. 

If this system is installed properly, and adjusted correctly, a single person can raise or lower the rig on the 30' Voyager with ease.

The installation of the #3023 Mast Raising/Lowering System is best accomplished in steps.  Therefore, follow the steps outlined below in the order they are given. 

Step A.  Figure 1 is a perspective drawing of the 30; Voyager with the #3023 Mast Raising/Lowering System in position, ready to lower the mast.  Figure 3 shows the relationship of all component parts of the #3023 Mast Raising/Lowering System. 

As shown in Figure 3, the 2-Hole Chain Plates (40531) must be bent to fit properly against the front surface of the mast and against the sides of the Lever Tube (41119).  The 2-hole chain plates should be positioned so the upper hole which will mount the Lever Tube is in line with the pivot hole in the mast.  This will allow the Lever Tube to be pivoted up against the front of the mast while not in use without causing excessive tightness to the Stabilizing Stays (41110) for the Lever Tube.  With the Lever Tube positioned on the centerline of the front of the mast, mark the six mounting holes for the 2-hole chain plates on the mast, drill 5/32" holes and install six #10-24 X 1" PH Machine Screws (40997).  The screws will make their own threads. 

Step B.  As shown in Figure 3, drill a 1/4" diameter hole through the Lever Tube 3/8" from one end to attach the Lever Tube to the 2-hole Chain Plates using 1/4"-20 X 2-1/4" HH Bolts (40825), 1/4"-20 Lock Nuts (20081) and two 1/4" Flat Washers (20045) between the 2-hole Chain Plates and the Lever Tube. 

As shown in Figure 3, attach a Bow Eye (20184) with the forward hole 1/2" from the forward end of the Lever Tube and passing through the Lever Tube perpendicular to the 1/4" hole previously drilled in the opposite end. 

Remove the forestay turnbuckle from the forestay and slide one end of the 5-5/8" Tang (40999) and the 1/2" OD X 12" Aluminum Tube (41122) onto the forestay and reinstall forestay turnbuckle. 

Step C.  The remainder of the installation is best accomplished with the mast raised.  Position the mast in the rear trailering crutch with the pivot bolt through the pivot hole in the mast and the mast base.  Attach the backstay and upper and lower shrouds as shown in Figure 3 if not previously attached.  For proper operation of the #3023 Mast Raising/Lowering System the upper shroud must be attached to the forward chain plate and the lower shroud attached to the rear chain plate.  Attach the main sheet with fiddle block to the stem head fitting using the Shackle (20114) and the Bow Eye (20184).  Also attach the 5-5/8" Tang (40999) which is on the forestay to the forward end of the Lever Tube using forward nut provided with the Bow Eye (20184). 

With the boat on a trailer or in the water have two persons holding a main or jib halyard on either side of the boat to stabilize the mast as it is being raised.  Also, have someone securely hold the Lever Tube vertical above the mast.  Begin hauling in the main sheet and proceed to raise the rig, keeping it as stable as possible.  When the mast has reached the vertical position, the backstay will become taut and the upper and lower shrouds should keep it vertical from side to side.  Always securely cleat the main sheet if the mast is to be stopped at any point while raising or lowering.  Keep a firm grip on the line with both hands during raising and lowering operations.  Attach the forestay turnbuckle to the stemhead fitting. 

Step D.  As shown in Figure 3 and Figure 4 slot the upper end of each 1" X 32" Compression Tubes (41124) 2" deep and just wide enough to accept the 1-1/2" Nylon Sheaves (40137) and the four 3-Hole Tangs (41276).  Drill a 1/4" hole through the Compression Tubes and install the 3-hole Tangs using 1/4"-20 X 1-1/2" HH Bolts (40131) and 1/4"-20 Lock Nuts (20081) as shown in Figure 4. 

As shown in Figure 2 install the lower mast base bolt and remove the pivot bolt from the mast.  Position the Compression Tubes between the upper and lower shroud on either side of the boat with the Nylon Sheave pressed forward against the upper (forward) shroud.  Sight over the tops of the Sheaves through the pivot hole in the mast base and mark the centerline of the turnbuckle attachment holes in the chain plates on the lower end of the Compression Tubes.  This dimension X (approximately 31-1/2") must be the same on each side of the boat.  This dimension may vary slightly from one boat to another and should be checked closely.  Once dimension X has been determined, drill a 1/4" hole through the lower end of the Compression Tubes parallel to the hole in the upper end at the location previously marked.  As shown in Figure 4, slot the lower end of the Compression Tubes as shown and attach to chain plates with the two 3-hole Tangs using 1/4"-20 X 1-1/2" HH Bolts (40131) and 1/4" Lock Nuts (20081) as shown in Figure 3. 

Attach the Compression Tube Stays (41111) to the Channel Stay Adjusters (40525).  As shown in Figure 4, attach the lower end of the Compression Tube Stays to the 7"-Tangs (40847) using the Shackles (20114).  With the adjustment pin of the Channel Stay Adjusters (40525) in about the middle position, stretch the Compression Tube Stays forward to the outboard surface of the deck coaming, as shown in Figure 3, and mark the mounting hole in the 7"-Tang (40847) on the deck coaming.  Drill a 1/4" hole in the deck coaming and attach the 7"-Tangs using 1/4"-20 X 1-1/2" HH Bolts (40131), two 1/4" Flat Washers (20045) and 1/4"-20 Lock Nuts (20081). 

Step E.  As shown in Figure 3 and Figure 4 attach the Stabilizing Stays (41110) to the Channel Stay Adjusters (40525) in a center adjustment hole.  Position the forward end of both Stabilizing Stays (41110) against either side of the Lever Tube (41119) and move the Lever Tube to the left or right as required so that the eye in the forward end of each Stabilizing Stay (41110) is straight across from the other.  Mark this point and drill a 1/4" hole through the Lever Tube (41119) and attach the forward end of each Stabilizing Stay (41110) to the Lever Tube using 1/4"-20 X 2-1/4" HH Bolts (40825), two 1/4" Flat Washers (20045) and 1/4"-20 Lock Nuts (20081). 

Step F.  Pull the main sheet with fiddle blocks tight and release the forestay turnbuckle from the stemhead fitting and push back on the mast while paying out the main sheet line gradually.  As the mast is lowered stop every few degrees and check the tension on the upper (forward) shrouds to be sure they are not becoming overly tight or slack.  Also, check the tension on the Stabilizing Stays (41110).  Both upper (forward) shroud turnbuckles should be loosened before lowering the mast but if the upper (forward) shroud becomes too loose or taut it may be necessary to adjust the Compression Tube Stays (41111) using the adjustment holes in the Channel Stay Adjusters (40525). 

If it seems necessary to stiffen or stabilize the mast base, Figure 5 shows a suggested method to assemble a wooden stiffener box.  This three-sided box must be just wide enough to slip over the outside of the vertical legs of the mast base.  The parts for the three-sided box are not included with the kit. 

If the #3023 Mast Raising/Lowering System is to be used on a ketch rig 30' Voyager, it will be necessary to shorten the Lever Tube (41119).  The Stabilizing Stays (41110) will attach closer to the forward end of the Lever Tube (41119) than when the system is used on a sloop rig. 

By pulling hard on the main sheet you will be able to gain the tension required to attach the forestay turnbuckle with ease.