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PostPosted: Mon Jun 04, 2007 12:57 am 
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This is the 'How To' portion of the small sail adapter for the 2007 AI. There were some changes for the '08 AI and Stringy has posted an updated How-to here:
http://www.hobiecat.com/community/viewtopic.php?t=8809

Regardless of what version you have, you can see the description and operation here:
http://www.hobiecat.com/community/viewtopic.php?t=6901

The finished product will look something like this:
Image

Parts:

I bought all the parts through Hobie or Home Depot. Here's what you need (reference picture below):

Hobie parts (all in black):
79512 mast collar (top left)
84550001 mast base, kayak (tube, right side)
79511001 mast base/pin (bottom middle)

From Home Depot (or any PVC supplier) -- note - Brands vary in size and style. These are made by DURA USA. All sizes are inches unless noted. Some trimming will be required. Best to take the mast collar along to verify fit:
1 ea -- 1 1/2 slip/slip coupler (lower middle)
2 ea -- 1 1/2 x 1 1/4 slip adapter (middle, attached to 1 1/4" pipe top and bottom)
1 ea -- 1 1/2 x 1 slip adapter (top right)
1 ea -- 1 1/4" PVC pipe x 7"

Misc. parts:
PVC primer and glue
epoxy -- find one that works with PE like 3M Scotch Weld DP 8010
one sheet, medium sandpaper
small stainless "S" hook
black paint/primer to suit
Image

Assembly:

All parts should be fitted dry before any gluing is done. This next pic shows pre-fitting the 1 1/2 x 1 1/4 adapter inside the mast collar. The lip here may need some sanding. Aim for a snug fit.
Image

The 1 1/2 x 1 adapter will fit into the top of the mast collar. It may not need trimming.

The kayak (small sail) mast base fits into this adapter. The inside bottom lip of the adapter will need some trimming to accommodate the tube. I used an exacto knife. If you want a flush mount (as shown), you will sand down the tube top flange. This is not necessary though. When fitted, it should look something like this (note tail of mast base protruding through bottom of 1 1/4 tube):
Image

Once the pre-fitting is complete, glue the 1 1/4 pipe to the trimmed 1 1/2 x 1 1/4 adapter. Epoxy the two adapters back to back, using any available tape to align them until set, as shown below:
Image

With epoxy, glue the 1 1/2 slip connector to the mast base/pin; glue the other (untrimmed) 1 1/2 x 1/1/4 adapter to the other end of the connector. Epoxy the preassembled insert into the mast collar. DO NOT GLUE THE 1 1/4 PIPE TO THE BOTTOM ASSEMBLY AT THIS TIME.
Image

Before continuing, you'll need to measure and trim the 7" tube length to replicate the correct height of your original mast base. Probably less than 1/4" trim (if any) will be necessary. Better to be too long than too short. Test fit this to your boat to verify before gluing! You will then need to carefully trim the small sail tube so that it seats in the bottom of the mast base/pin. Double check these parts dry until you're satisfied you have it right.

Glue the 1 1/4 pipe (with top assembly) to the bottom assembly. Insert and glue the small sail tube so that it is glued at the base and top. When done, it should look like this:
Image

Bevel this lower shoulder as shown to ease extraction of the adapter:
Image

Modify your "S" hook to permanently fit your bungee. It will hook to your adapter as shown:
Image

Prime and paint to suit. 8)

Revision -- I originally used JP Weld epoxy. Unfortunately it eventually failed. You may need a glue that can bond with PE. The only one I know of is now listed on the materials list above. Here's a link that gives a little more info on glues: http://www.hobiecat.com/community/viewt ... b166a57a27
Perhaps DuPont has an equivalent? Good luck!


Last edited by Roadrunner on Thu Feb 28, 2008 9:26 pm, edited 2 times in total.

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PostPosted: Mon Jun 04, 2007 6:22 pm 
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Very nice write-up. One question, where did you get the Hobie parts?

Thanks, Ray J

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PostPosted: Mon Jun 04, 2007 8:48 pm 
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Location: Escondido
Thanks, Ray.

Just got them locally. Hobie had to supply a couple of the part numbers, since they are not all in the current catalog. Your local dealer can verify these numbers and descriptions with Hobie, but I'm pretty sure they are right.

Maybe when Matt gets back in town he can confirm this. 8)


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 Post subject: Great post
PostPosted: Tue Jun 05, 2007 3:44 am 
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All ten of my thumbs very impressed by another great post.

Thanks for the ingenuity and hard work!


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PostPosted: Tue Jun 05, 2007 4:20 pm 
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Location: Florida
Roadrunner. Like I suspected, the easiest way to build a mast adapter was to get some of the parts Hobie used on the Island's mast. No elaborate re-fabrication requied, just a little plumbing - great pics & instructions.

With these mast parts available one could go about building any kind of custom mast that would roller-furl.

Maybe a mast/sail smaller than the current Island setup but bigger than the little Hobie sail kit for its other kayaks.

Perhaps such a mast adapter could be made that doesn't add any mast or sail but instead a pole holder, fish finder mount or whatever.

Let the mods begin

Yakaholic


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PostPosted: Wed Jun 06, 2007 7:58 pm 
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Posts: 615
Location: Hawaii, Big Island
RR
You need to post that on KFS

Wasn't there a NZ guy (stubbo?) trying to do this?

Great Job.

Now if I could get you to work on a beach umbrella U joint to let the AI mast collapse.....I could at least contribute a carbon fibre tube made to a specific diameter as a sliding locking collar. West systems provides the instruction

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PostPosted: Wed Jun 06, 2007 9:44 pm 
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Don, haven't seen your posts in awhile -- good to hear from you. Did you get your AI yet? Life is short and you're not getting any younger! :wink:

Yak, that's a great point about being able to adapt about anything to the roller base. What do you think about a Lazy Susan for baits, fillet table and sandwiches? You could work while you dine! :lol:

Dan, interesting idea, but I see several potential problems. 1) cost of SS roller bearing U-joint with custom mast inserts; 2) sleeve needs to be big enough, have room to slide and securely latch without raising sail height(requiring mast extension); 3) I can picture a big gust splitting the sleeve or mast (mast flex focusing great pressure at top of sleeve), dumping the entire sail overboard; 4) lowered mast on deck would put a big limitation on movement. This isn't to say that it couldn't be done -- just factors to look at.

As an alternative, what about reefing the sail and passing your rod around the mast? Remember, you can stand up right next to the mast or move around on this rig with the sail furled. It isn't a very high tech solution, but you can't beat the price and the simplicity makes it very compelling! 8)


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PostPosted: Fri Jun 08, 2007 1:05 am 
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Hobie Team Member

Joined: Wed Dec 07, 2005 11:04 pm
Posts: 615
Location: Hawaii, Big Island
rr

I have a 3 pronged attack for getting an AI:

a. Sell the '06 Adventure (not getting any nibbles. everyone wants the latest model at Hobie prices.)

b. Reinforce the '06 hull for the Ai mast step. Not so far out now given west systems G-Flex epoxy ( http://kfs.infopop.cc/eve/forums/a/tpc/ ... 5631010483 )

c. Build my own hull and buy the AI sail kit add on $1550 (also required for b above ) I have Matt at JEM designing a hull now.(includes my 6' fish box lined with removable insulated bag and unique rod storage below decks)

The mast thing is still a sticky item though. Passing the rod around the mast just doesn't seem like an option to most guys here fshing for pelagics.

Striking it may be possible. My test of the AI ran out of gas in 25 knot wind with a rudder failure. However, I have done that with the smaller sail and fish around 35-40lbs. Open to question until I hook up a bill fish.

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 Post subject: Part number correction
PostPosted: Fri Jun 08, 2007 10:04 am 
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Part number correction:

Hobie parts (all in black):
79512 mast collar (top left)
84550001 mast base, kayak (tube, right side)
79511001 mast base/pin (bottom middle)

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Director of Parts and Accessory Sales
Hobie Cat USA


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PostPosted: Wed Aug 29, 2007 9:09 pm 
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This is a correction to the orignal post.

Sorry to say, the JB Weld epoxy eventually failed. The original posting has been revised accordingly -- you may need a glue that will bond with Polyethylene. I'm not sure what the Hobie materials are, but have had good luck with the DP 8010. If anybody has other suggestions, please chime in. I'll continue to look for an inexpensive easily obtainable alternative as well. 8)


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PostPosted: Tue Sep 25, 2007 7:36 pm 
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