Carbon Fiber Anchor Roller & Stealth Nav Lights – Finishing Paikea’s Front End

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Key Message: With the major structural work complete, we’re adding the final functional details to Paikea’s new carbon front end. This post covers the fabrication of a custom carbon fiber anchor roller, the installation of stealth navigation lights hidden within our America’s Cup mast bow pole, and the upgrade to a raised trampoline track system—transforming the bow into a clean, capable, and cruise-ready platform.

Author: Shayne and Anna

The Final Touches: Carbon Anchor Roller and Stealth Navigation Lights

The transformation of Paikea’s front end is nearly complete! In this final phase, we’re tackling the crucial finishing details: designing a custom carbon fiber anchor roller, raising the trampoline tracks for better performance, and installing cleverly protected navigation lights into our recycled America’s Cup mast bow pole. With our departure deadline approaching, every detail counts.

Raising the Game: New Trampoline Track System

One of the most visible changes is raising the trampoline attachment points significantly higher than the original design. We removed old hatches and laminated new PVC tracks reinforced with carbon fiber to create a cleaner, more functional system.

The new system features:
  • Higher attachment points for better trampoline tension
  • Carbon-reinforced PVC tracks for durability
  • Stainless steel rods through slotted openings for secure tie-offs
  • Integrated design that maintains the clean lines of our carbon front end

This upgrade not only improves functionality but also enhances safety and comfort when moving forward at sea.

Carbon Fiber Anchor Roller: Custom Design for Our Beam

With the new carbon beam requiring completely custom fittings, we designed and built a dedicated carbon fiber anchor roller assembly. Located strategically on the front beam, this custom solution maintains our commitment to using carbon fiber throughout while ensuring reliable anchor handling.

The roller integrates seamlessly with the beam’s geometry, proving that custom solutions often outperform off-the-shelf options when working with advanced composites.

America’s Cup Secrets: Repurposing Masthead Hardware

Our bow pole, made from a 2007-era America’s Cup mast section, contains fascinating engineering history. As someone who actually built these masts for the Cup, I can reveal the original purpose behind the hardware we’re repurposing:

  • Masthead Halyard System: The main sail was hoisted using repurposed spinnaker halyards, with a crew member at the masthead to manage the complex locking mechanism
  • Aerodynamic Fairings: The intricate shapes we’re working with were originally designed to minimize wind resistance at the masthead
  • Backstay and Jumper Attachments: The various pins and fittings served critical structural functions in the racing rig

Understanding this history helps us make informed decisions about how to modify these components for their new life on Paikea.

Stealth Navigation Lights: Protection Meets Function

After careful consideration, we installed the navigation lights in a protected location within the bow pole itself. Here’s why this unconventional placement works:

The Problem with Traditional Placements:
  • Lights on the bows get constantly wet and corroded
  • Lights on the martingale are vulnerable to sheets and tack lines
  • Lights on the mast require complex gimbaling systems
  • Code zeros and spinnakers can block lights on lower positions

Our Solution:

We created carbon fiber channels inside the bow pole fairing, then:

  • Cut precise openings for light visibility
  • Built protective carbon angle frames
  • Will foam and fair for aerodynamics
  • Positioned high enough to avoid sail blanketting

This placement keeps the lights protected from lines and sails while maintaining clear visibility and legal compliance.

The Final Push: Paint and Preparation

With all components in place, we’ve moved into the final painting phase using a professional-grade epoxy urethane primer from the race boat world. This system:

  • Bonds exceptionally well to carbon fiber
  • Provides good build for surface finishing
  • Withstands marine environments
  • Creates the perfect base for final topcoats

The decision to paint everything black, while thermally challenging in sunny climates, completes the dramatic transformation of Paikea’s front end.

Conclusion: A Completely Transformed Front End

From recycled America’s Cup mast to fully functional cruising system, Paikea’s new front end represents the perfect blend of high-tech materials and practical cruising needs. The carbon anchor roller, protected nav lights, and raised trampoline tracks demonstrate how careful planning and quality craftsmanship can create solutions that are both beautiful and functional.

As we race toward our departure deadline, these final details ensure we’ll have a safe, reliable platform for the adventures ahead.

Follow our Entire Front Beam Transformation:

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