Composite components
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COMPOSITE COMPONENTS TUBES & PARTS MANUAL PASSION I TECHNOLOGY I DESIGN I PERFORMANCE ONE DESIGN SPARS | COMPOSITE COMPONENTS

ONE DESIGN Precise consistency. Southern Spars’ One Design business is dedicated to supplying production rigs, from high performance dinghies up to 60 foot performance cruisers. It also produces composite components such as spinnaker poles, sprits, booms, glass and carbon tubing, sail battens, stanchions, masthead wands, tillers and extensions. Southern Spars’ One Design manufactures in both Cape Town and Auckland enabling fast delivery and minimum shipping hassles for most destinations. Male moulded dingy masts, spinnaker poles, sprits and stanchions are manufactured in New Zealand All...

PRODUCT RANGE High performance carbon fibre and composite products with an emphasis on value for money. Masts Production Sports Boats & Keelboats up to 60ft Dinghy Classes from Junior One Design to Olympic Spinnaker Poles Tapered and parallel poles. Sold as bare tubes or complete poles Sprits (Prods) Custom built as required Tapered or untapered Mandrel range suitable for boats up to 45ft Booms Complete or bare tube Kitset parts available Glass & Carbon tubing General purpose use from 5mm – 150mm Custom laminates and stock tubing available Sail Battens Carbon and glass options available...

MAST SECTIONS Manufacturing methods are varied to deliver the most cost effective method of production for a given tube or part. Larger size One Design rigs are built in female moulds. The tubes are produced in one piece by blowing up a bag (bladder) inside the tube to put the required amount of pressure onto the laminate. This pressure is similar to that achieved in an autoclave, and once under pressure the self-heating moulds are switched on to cure the tube at 120°. Using a female mould on larger tubes produces a more efficient high performance laminate as the fibres are stretched as...

TUBING Southern Spars are the exclusive suppliers of Kilwell tubing to Yachting related projects. The male moulded tubes are designed by the Southern Spars design team in Auckland and manufactured by Kilwell Fibretube in Rotorua. Spinnaker poles, stanchions, dinghy masts and other tube products are then completed in the Custom Projects factory in Auckland. Glass stock tubing has 80% fibre at 0° and 20% at 90°. Carbon stock tubing has one wrap of glass at 90°; the carbon content is all at 0° orientation. Custom tubing is available utilising any of the mandrels as listed in the Mandrels...

STERN TUBING TUBING Code ID (mm) OD (mm) Wall (mm) Stocked Item ST38 38.1 44.4 3.15 Yes ST44 44.4 50.4 3.00 Yes ST50 50.8 63.5 6.35 Yes ST60 60.3 73.0 6.35 No ST66 66.7 76.2 4.75 Yes ST76 76.2 89.0 6.40 No ST79 79.4 92.1 6.35 No ST85 85.7 101.6 7.95 No ST95 95.0 114.3 9.65 No ST108 108.0 133.0 12.50 No ST127 127.0 133.5 3.25 No SAIL TRACK Code ID (mm) OD (mm) Wall (mm) Stocked Item 1.5 Stock Length (m) 2.9 120/150 12.0 15.0 120/150/ 3 12.0 15.0 1.5 2.9 Yes Yes Stock tubing is available at the current prices found on our website @ www.southernspars.com > Components > By Product > Tubing....

MANDRELS Mandrels are used to laminate male moulded tubes. Pre-preg carbon fibre and/or fibreglass is wrapped around the mandrel. This material can be laid at any angle to suit the engineered requirement of the tube. Typically a basic laminate has 80% laid at 0° and 20% at 90°. Each layer of fibre is rolled under pressure to compress the laminate as much as possible. The laminated mandrel is then wrapped in a strong heat shrink tape and hung vertically in an oven at 120°. The bare carbon finish is suitable for most applications with the light spiral effect from the tape remaining....

SPINNAKER POLES Carbon poles give a significant weight saving over alloy, making crew work a lot easier and reducing weight in the bow of the boat. Choosing the right pole: A boat with a higher than usual righting moment may require a slightly heavier pole Particularly large spinnaker/gennakers may require a heavier pole A pole that is only used for running can be lighter than an all-purpose pole which will also be used for reaching Choose the correct tube for your boat based on pole usage; boat righting moment and spinnaker size Poles can be selected based on pole length Spinnaker poles...

SPINNAKER POLES SPINNAKER POLE SELECTION CHART Select your pole based on pole length There will be more than one option for a given length Choose the correct tube for your boat based on pole usage, boat righting moment and spinnaker size. A pole only used for running can be lighter than an all-purpose pole which will also be used for reaching. A boat with a higher than usual righting moment might require a slightly heavier pole Particularly large spinnaker/gennakers might require a heavier pole PASSION I TECHNOLOGY I DESIGN I PERFORMANCE PARTS MANUAL I ONE DESIGN I www.southernspars.com

STANCHIONS Composite stanchions offer more flex and greater ability to withstand impact without breaking. All stanchions are designed and built to meet the required safety regulations and can be supplied with compliance certificates if requested. Currently approved in USA, France, Australia and New Zealand. Stock stanchions supplied undercoat only Stanchions can be painted to match boat colours Supplied in stock or custom sizes Options to suit socket or spigot mounting Stainless steel bushes on all wire lifeline holes Composite bushes available for spectra lifeline holes Roller tops...

ONE DESIGN CLASSES Rigs and spare parts are available through the following suppliers: 49er New Zealand Australia USA Europe MELGES 24 USA Europe MELGES 32 USA Europe MUMM 30 USA Europe Asia FARR 40 USA Europe Mackay Boats Bethwaite Design Vanguard Sailboats Ovington Boats dave@mackayboats.com info@bethwaite.com vscsc@teamvanguard.com niners@ovingtonboats.co.uk Melges Boat Works Devoti Sailing s.r.o. sales@melges.com sales@devotisailing.com Melges Boat Works Melges Europe sales@melges.com f.michetti@fredworld.it Rig Pro Stagg Yachts Rig Pro DK Yachts chuck.brown@southernspars.com...