So I put the sail on in the front yard today, and same problem arose. I loosened each furler nut in a star pattern a few turns from where the dealer had it tightened to, which had slipped previously, so I could reposition it in the correct spot. Got it positioned and tightened the furler up going little by little in star pattern, and probably a couple more full turns on each nut than before.
After just once completely furling the sail from the fully open position, the furler slid up a noticeable amount on the mast. I managed to pull the furling line enough (as it was beginning to slip around the furler) to completely unfurl the sail, and the furler rode up the mast to the point where the retaining cord became taught. At that elevated line angle from fairlead to furler, operation no longer works. I once again repeated the loosening and tightening of furler into correct position, and repeated the test with the same results.
I took pictures of the overall setup, one of the furler in correct position, and another from same angle showing how much higher the furler sits after completely furling one time. This is in yard sitting in kayak with no wind, and pulling very slight tension on main sheet while furling. I do think where I connect the aft end of bungee cord securing the furling line could be about 3" further back, but tested it while pulling a little more tension (which decreased slippage of line around furler) on furling line with same result of furler climbing up.
As a note, I installed on port side due to anchor trolley being on starboard side. The picture shows the line laying as I operate the furler, but once finished using I can just slide the lines slightly outboard and the tension of the line holds it under the installed factory side carry handle, and gives no interference with rudder knob.
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