The steady evolution of roller furling has paralleled the increasing popularity of the gear for both coastal and offshore sailing. The formula is simple: make sails easier to handle and people will use them more and have more fun doing it. Without doubt, roller furling systems make it safer for two people to handle an ocean sailing boat, which is why, for many offshore sailors, roller furling headsails are at the top of their "must have" list.

In past two years the major manufacturers of roller furling headsail systems have upgraded their products. In the accompanying table (page 6), we take a comparative look at the six best systems as specified for boats from 35 to 45 feet.

Three of the systems -Harken, Hood and Schaefer - are similar in concept with variations in design and engineering. The emphasis among them is to deliver reliable products at competitive prices and to sell as much volume as possible through the major catalogs, West Marine and BOAT/US. The competition between these companies and the low margins demanded by the catalogs has benefited consumers. The systems are easier to assemble than in years past -in response to the direct purchase market- and prices have remained low with deep discounts offered. This year, Profurl is making a foray into the catalog market, which should have a favorable effect on its price.

The two other European systems we look at do not compete in the catalog market but sell direct or through sail makers, rigging shops and boat yards, hence their prices are slightly higher than the America-built systems. But the European systems have found markets in North America. Furlex has a good reputation among offshore sailors as a system that stands up to hard use and performs under heavy loads, while Reckmann has carved out a niche in the high-end, luxury market.

Hood Seafurl - Model 3250:
It is appropriate to lead off with the Seafurl system because Hood Yacht Systems was the first to manufacture and distribute widely the type of roller furling systems we know today. That was two decades ago. While the company no longer is owned and operated by Ted Hood and his family, the product continues to evolve. Pompanette Inc. in New Hampshire now manufactures and markets the systems.

This year Hood has introduced the new Sea Furl 5, which uses stainless-steel bearings in open spherical races, has a polished stainless-steel drum and can be rigged over an existing headstay. The system is priced competitively and looks attractive but to date has not had enough sea time to be ready for evaluation.

The Sea Furl Model 3250 is a workhorse of the Hood line, targeted at boats in the 35 to 45-foot range. The unit employs stainless-steel bearings with Delrin spacers in open races in the main drum and in the halyard swivel. While robust, stainless steel is a tricky material that can corrode or crack unexpectedly. Moreover, open races for the bearings mean the stainless steel will be exposed to salt, dirt, and other elements, all pointing to surface corrosion and friction inside the bearing race. The manufacturer instructs owners to flush the bearings regularly with fresh water and keep the system well sprayed with lubricant.

Hood's patented double-swivel system for the genoa's tack and head provides a good solution to the chronic problem of poor sail shape when the genoa is partially rolled up or reefed.

While a good name in offshore sailing, Hood Yacht Systems is a company in transition. The existing models, including the 3250, have been proven by long use and several have made circumnavigations, although the system requires more maintenance than some others. Look for improvements in the new Sea Furl 5 -for boats with head stays up to 10mm (3/8-inch)- and the systems Hood develops to follow it.

Harken Unit 2 - Mark II:
Although the Harken brothers, Peter and Olaf, did not hurry into the roller furling market following the early success of the Hood systems, when they did jump in they did so with their usual style: full speed ahead.

Because the product was designed for the mass market of coastal and lake sailing boats, the systems were not conceived with heavy blue water sailoring in mind. That is not to say that the Mark II versions are not offshore systems. They are. But in events such as the BOC, the units have required modification and repair in more than a few instances.

The Mark II systems use Torlon bearings in open, double, bronze races. Torlon is a space-age plastic that has demonstrated a resistance to compression and cracking under load. Harken believes so firmly in the material that it offers a seven year warranty on the system. The caveat, however, is the need to rinse the bearings regularly. Wear and tear on the bearings is not due solely to compression. Salt crystals and air-bourne dirt get into the races and grind the surfaces of the Torlon balls, gradually deforming them. While this process may not present a problem for boats with access to ample freshwater, it is certain to be a problem when sailing in remote and dusty regions such as Mexico, North Africa, Australia or the Red Sea.

That said, the Harken systems can be installed and maintained by a handy amateur, are well designed and manufactured and deserve their good reputation. If price is your main criterion, then the Harken Systems should catch your eye.

ProFurl - System C42:
Profurl first made its name in the US when Philippe Jeantot won the first BOC Round The World Race with the otherwise unknown French system on the bow of Credit Agricole. Jeantot's performance in that race so dominated the fleet that his choice of gear -roller furling in particular- captured the attention of many offshore sailors. In 1983, there were still many American sailors who would not sail offshore with such a contraption. Jeantot changed that forever.

Profurl units are known for their sealed, carbon-steel bearings, heavy construction and reliability. They are also known as the most reluctant to turn. With truck bearings sealed in packed grease, the system never free-wheels easily and even in light breezes offers resistance. However, when the wind is howling, the system can be cranked in without concern for the bearings, which will withstand many tons of compression. The down side to sealed bearings lies in the problem that arises when and if the seals fail. While bearing failure in a Profurl system is extremely rare, the solution has normally been to replace the whole defective unit rather than try to rebuild and repack the races -not an easy thing to do if you're miles off the beaten track.

Profurl uses both elliptical and round extrusions joined with hard plastic bushings, aluminum joints and stainless-steel screws. This system is strong and easy to assemble but involves dissimilar metals that will corrode quickly unless they are isolated with sealant or LokTite. Those who sail for long periods with the Profurl systems find it worthwhile every year to loosen all the screws along the full length of the headstay and re-bed them with fresh bedding.

Halyard wraps are a serious concern when using a roller furling system. Profurl has developed the patented "Wrap-Stop" device which fits at the top of the foil. The halyard attaches to a tang on the top of the top swivel which slides into place behind the Wrap-Stop, preventing the halyard, once tightened, from turning with the swivel. This system works well and can save a disaster at sea.

One of the aspects we like best about the Profurl systems is the way it fits directly over an existing headstay. By tying off the bottom section directly to the bottom toggles via stainless-steel extensions, the side loads when reefing are transferred to the strongest element in the rig, rather than to the drum or torque tube. Moreover, should the system have to be removed, it can be slipped off the stay without removing an end fitting.

Profurl has earned it's "offshore" stripes through extraordinary reliability. In the last BOC Round The World Race every finisher of the 27,000-mile event had Profurl systems onboard -even those who started with other systems. With a Blue Water Rating of 8, we recommend Profurl Systems for extended offshore sailing.

Schaefer 3100:
Just over a year ago, Schaefer introduced its re-designed system incorporating many new elements gleaned from experience with earlier units. The new generation has given up sealed steel bearings and gone to open-race Torlon bearings, set in three high-tech races. While this change allows the drum and extrusion to spin more easily around the headstay, and therefore makes reefing and furling easier for 98-pound crew members, the convenience may be at the expense of some measure of strength and durability.

The installation requires cutting an end off the headstay and sliding the system on. To avoid a weak link at the point of highest strain -the bottom shroud terminal- Schaefer recommends cutting the top end and sliding the system down rather than up. The drum sits over the original turnbuckle, making forestay adjustments easier than on some units.

In the redesign of the system, Schaefer opted to use the simplest possible method to join the foil sections. A simple plastic bushing was designed to fit around the stay and inside the extrusion, which is then pop-riveted to the extrusion sections. This positive attachment is light, strong and can't work loose. When the system has to be broken down for repairs, the rivets can be drilled out and replaced with new ones.

Although Torlon is not our first choice for bearings, the new Schaefer units are well made and should be reliable offshore.

Furlex 62C:
Furlex roller furling systems are so popular in Europe that the company may well hold a leading position in world market share for such systems. But, to date, Furlex has not made as deep an in-road into the North American market, largely, we suspect because they are not sold through the catalog houses. Yet, even at the suggested retail price, Furlex units represent good value for money.

The Furlex system is similar to the design initiated by Hood many years ago. In the interim, the Hood product has not progressed with the same attention to detail as has the Furlex. Built in Sweden and supplied in a very complete and logical do-it-yourself installation kit, the Furlex system is a good compromise between performance, durability and price.

One of the problems Furlex has addressed better than its competitors is the wear on bearings caused by the vertical loading of the halyard on the bottom races. The company has developed and patented a "Load Distributor" bearing that floats in the horizontal plane, permitting more of the bearings in the race to carry the vertical load. As the sail is reefed and the load rotates around the stay, the floating bearing moves with it. This not only saves wear and tear on the lower bearings, it makes reefing under load easier and potentially safer.

For boats going to sea, the durability of the interior bushings, insulating the extrusions from the stays, is a concern. Furlex goes the extra mile in this category by supplying pieces that fit the full length of the stay, keeping the wire or rod isolated from he extrusion. The joints are assembled with spring clamps of the type used by Hood. While this is a proven method, it is not idiot proof and should be set up with care. Bedding the clamps in non-corrosive silicone or Sikaflex makes sense. A new headstay and Norseman terminal are supplied with each new system.

Despite the high quality of the package, Furlex makes the headstay adjuster an optional extra -normally relying on back stay tension for the head stay adjustment. This seems an unusual omission. For our money, the next improvement in the design should be an integral turnbuckle. Still, Furlex systems have earned an excellent reputation as all-around units capable of making many miles and, with a Blue Water Rating of 8, we can recommend them for extended coastal and offshore work.

Reckmann R2-2000-30:
Attention to detail and fine engineering are what set the Reckmann systems apart from the rest and no doubt account for the high price. The manual Reckmann systems evolved from the larger hydraulic systems designed for mega yachts. Price has always been a secondary consideration in a market that puts style, reliability, service and reputation ahead of other more mundane concerns.

The 2000 series brings some of these qualities into the wider market of manual systems. The bearings used are precision roller bearings packed in semi-closed, greased races. Unlike ball bearings, rollers spread point loading over a wide bearing surface.

The foil sections fit over a full-length bushing, which isolates the headstay from the turning sections. The section joints are stainless-steel brackets and screws, set up so no dissimilar metals are mated. Sealing the fastenings with LokTite will be a good precaution. Despite stainless-steel construction, the Reckmann systems weigh the same or less than most of the other systems. The combination of lightness with durable and attractive stainless-steel construction definitely sets the systems apart. If cost is not your first concern, then the Reckmann 2000 is your best bet. We give it a Blue Water Rating of 9 and would be happy to sail with the system anywhere.