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Restoring discontinued ProFurl LC42 and N42 headsail furlers requires replacing internal bearings, seals, and snap rings with off-the-shelf components. Because the aluminum extrusions and castings are no longer manufactured, the rebuild focuses on the lower drum units and upper swivels. To disassemble, use a small pick to expose the seal, then drill two holes in the cover to extract it with screws and a slide hammer. Heating the aluminum housing in an oven to 250°F allows the bearings to be pressed out or tapped through without damaging the casing. Use carbon steel bearings rather than stainless, as stainless steel deforms under the high loads of a furling system. After cleaning, fill scratches in the aluminum with JB Weld and smooth with a file. During reassembly, use PVC pipe sections as custom bearing drivers to ensure even pressure and prevent side-loading. Lubricate with Tef-Gel to isolate metals and protect against water intrusion.

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