Some of my lower sail battons (particularly the one immediately above the boom) seem to be extending part way past the sail side edge of the mast when my Gastra 7m sail is fully rigged. I have a similar problem but not quite as bad with a smaller 6.0m sail. This has the effect of needing a good flick on the boom to have it "pop" over to the leeward side of the mast once changing tack. Is this correct rigging? If not how do I get them in the correct position. Is it by more downhaul/mast bend. I seem to have the sail down hauled as far as I physically can. Any further would require additional mechanical assistance other than the pully system provided. I believe I am using the correct mast length although I do use a mast step extension for the 7.0m sail. Any suggestions? I fear I am going to break something particularly next time it blows.
Could be perfectly normal, you'd need another owner of same sail to confirm.
My old KA's rig like this, and for minimum outhaul on my newer KA Koyotes I'll have the batten above boom about half way across mast. They flick around without needing any extra pop though.
Put some weight on the window of the sail to check how much draft you have, If you can touch the boom on the other side, it's probably too much and you need more outhaul or downhaul.
If the leech is nice and loose, and you don't have too much draft, you'll either have to learn to live with it or get a better sail.
This is a pet hate of mine, big sails that need a lot of wind to rotate them and fill them out. Big guys don't have such a big problem with it, but for light weights like me, this sort of sail can be unusable in the wind range I need it for.
Think the 7.0 like this that hardy lent me was also a Gastra but can't be certain.
My wave sails have stacks of draft and even on the lightest wind setting all battens are behind the mast, means they rotate instantly and are fully filled out in about 10kts.
I have a gastra 7m Pilot & sounds like more downhaul needed, even set mast extension higher so you can get more downhaul...
make sure you downhaul til you start getting looseness in the top part of leech
You said:
"I seem to have the sail down hauled as far as I physically can. Any further would require additional mechanical assistance other than the pully system provided"
...but this should be beside the point. Regardless of how difficult you find it, the sail needs a certain amount of downhaul in order to be rigged properly.
Perhaps try to rig it with some expert help, eg at the beach with more experienced windsurfers around, who will help while they are drinking the cold beers you have just given them?
If the top of your sail looks like a plastic bag flapping in the wind and the battens are still that far past the mast your mast is 2 stiff or has the wrong bend curve. If your sail is really flat and the battens are past the mast you need to apply more downhaul. If you struggle to get enough using your own power (and your harness bar) then force some nice big guy on the beach to do it for you. your bottom battens should be sitting roughly in line with the middle of the mast.
Could be the wrong mast too.
Gaastras, I believe, have a hard top curve. ie they are relatively soft in the bottom.
An NP mast and some others are soft top and relatively stiff in the bottom. If you are using one of these you will need quite a bit more downhaul than specified to bend the bottom of the mast sufficiently. This will make the top of the sail very loose.
If your downhaul pulleys are all good and you have the downhaul wreathing right you should be able to downhaul a 7 with no more mechanical assistance than a tug cleat or hydro puller or similar. You might try some Formuline downhaul rope too. That makes it easier.
When you go to buy a new sail even if its in a shop take your mast and try the sail out. All shops should let you do that.
