Worn foil to foiler drum joint. Solutions?

[MM5AHO]

I noticed the other day that the end of my Harken furler foil is word at the point where it enters the drum mechanism, such that the clamp on the drum top doesn't actually grip it, and the two can become detached.
The foil has a short piece below the sail entry point (where sail slides into foil) of about 500mm. I wonder if just changing that piece would be a reasonable fix?
The foil is the type that is aluminium extrusion, has dual sail slots, and it approximately oval in cross section. It's an older style. Mk1.

 

[Poignard]

I don't know that type of furler but might it be possible to cut a bit of the foil off so that an unworn part then enters the drum?

 

[lpdsn]

I noticed the other day that the end of my Harken furler foil is word at the point where it enters the drum mechanism, such that the clamp on the drum top doesn't actually grip it, and the two can become detached.
The foil has a short piece below the sail entry point (where sail slides into foil) of about 500mm. I wonder if just changing that piece would be a reasonable fix?
The foil is the type that is aluminium extrusion, has dual sail slots, and it approximately oval in cross section. It's an older style. Mk1.

I think I understand what you're saying, although a picture or two would help to remove doubt. Is it only the foil that is worn? I presume it is corrosion between Al and stainless steel.

Replacing it could work, or even cutting 20 or 30mm off the bottom.

How easy is it to remove your furling gear? Although my furling gear and forestay can be removed as one, the forestay has to be cut to allow the furling gear to be taken apart, which means it isn't a quick and simple job. If yours is easier to disassemble then it probably wouldn't be too difficult to take it apart, trim a bit off the end of the foil then refit it with appropriate quantities of Duralac or equivalent to inhibit further corrosion.

A lot also depends on your mast and how well it would stay up without a forestay whilst your doing the job. Obviously you can use halyards to the cleats - dyneema better than stretchier stuff - and take the boom & sail off to ease the loads, but a lot will also depend upon whether it is fractional or masthead and whether it gets extra support through being keel stepped.

 

[garvellachs]

We have a similar furler. I think it can be taken to bits leaving only the internal guides for the foils on the forestay - all the rest can be removed. That short section of foil serves only to hold the rest (incl the feeder) above the drum so it's just a spacer really; I guess you could turn it round and put the worn section above. Or you could just move the whole foil up or down a bit if the genoa length allows it? Or raise the foil a bit and fill the affected area and sand it smooth?

 

[MM5AHO]

The forestay can be removed without demounting the mast. Its not keel stepped, but the shrouds will hold it up with no loads on the mast.
The short piece of foil that's worn only for about 25mm is the lower end of the bottom section which is below the feeder, and about 500mm long.
It seems to be only the foil that's worn, rather than corroded. It enters what harken call the torque tube, which is also aluminium.
Its done a lot of work over many years, so not too surprising to be worn.
Shortening the whole foil by trimming the worn bit and moving down doesn't look good, as the genoa is full height (not fractional rig either).
I think that getting a piece off a scrapped foil might be best answer.
Thanks for ideas.