Engineering Paikea’s Rig: Adapting America’s Cup Technology for Cruising

Leave a Comment / Boat Systems and Upgrades, Carbon Mast, Paikea Refit, Rigging & Systems, Sailing Techniques, Working with Composites / By

Key Message: The successful adaptation of an America’s Cup mast for cruising proves that high-performance engineering and practical, safe operation are not mutually exclusive. Every decision—from the rotating system and custom spanner to the choice of simple lowers over spreaders—was driven by a core principle: optimize for real-world strength, safety, and simplicity. This rig is not a collection of expensive parts, but a thoughtfully integrated system where each component serves a clear purpose, demonstrating that true performance is defined by intelligent design, not just exotic materials.

Author: Shayne and Anna

Introduction

The heart of Paikea’s performance transformation is her ex-America’s Cup carbon fiber mast, rescued from disposal and adapted for cruising use. This wasn’t a simple bolt-on upgrade but a complete re-engineering project that required balancing performance gains with practical cruising needs. The decisions made during this conversion reveal important principles about rig design that apply to any performance-oriented vessel.

Mast Conversion: Rotating vs Fixed Configuration

The choice to make the mast rotating was driven by both performance and safety considerations:

  • Structural Foundation: Utilizing the existing mast ball system provided necessary movement accommodation in the multihull platform
  • Safety Control: The large chord dimension created significant windage that needed active management in heavy weather
  • Conversion Simplicity: The alternative fixed configuration would have required additional structural fittings without providing the control benefits

The rotating system allows the mast to be feathered when not in use, reducing loads on both the rig and anchor system.

The section is so large we use the mast as our 5th reef and because of this we do rotate this mast.

We mounted the rig on Paikea with a ball and socket arrangement. This was done as it allowed us the option of either fixing or allowing the mast to rotate. To be able to move and rotate the mast makes a huge difference to the sailing performance although it does mean that our wind instruments need to be mounted with a gimble to allow for the rotation.

Custom Spanner Design: Multi-Functional Solution

The rotating system required an innovative approach to control:

  • Integrated Steps: The spanner arms double as safe access points to the forward deck area
  • Clean Deck Layout: Avoiding protruding hardware that could interfere with movement or locker access
  • Halyard Management: Providing outboard lead points to reduce halyard slap against the mast
  • Future Refinement: Planned centerline lead point to improve mechanical advantage at high rotation angles

This solution demonstrates how functional requirements can be addressed with multi-purpose design.

Rigging Philosophy: Lowers vs Spreaders

The decision to use simple lowers instead of a spreader system was based on structural analysis and practical considerations:

  • Aerodynamic Efficiency: Eliminating six wires significantly reduced windage, with noticeable improvement in anchoring behavior
  • Structural Adequacy: The mast tube’s inherent fore-aft stiffness made spreaders unnecessary for this application
  • Simplicity: Lowers required only two attachment points versus the complexity of spreader roots and associated rigging
  • Weight Savings: While not the primary driver, the simpler system contributed to overall weight reduction

This approach maintained necessary strength while optimizing for the cruising environment.

Instrumentation and Control Systems

The rig incorporates several thoughtful systems for practical sailing:

  • Dual Wind Sensors: Redundant instruments ensure reliability for wind-based autopilot operation, with the upper unit positioned in clean air above sail interference
  • Mast-Mounted Winch: Enables single-handed sail handling from the working area rather than requiring movement to the cockpit
  • Strategic Control Placement: Halyards for spinnakers and code sails at the mast where they’re used, while reefing and furling controls remain in the cockpit for daily operation

These choices reflect a deep understanding of how the boat is actually sailed across different conditions.

Unique Jib Halyard Solution

The jib tensioning system represents a thoughtful compromise:

  • Simplified Hardware: Eliminates the need for dedicated winches and clutches at the mast base
  • Luff Tension Control: Uses a lashing system at the furler for fine adjustment
  • Practical Compromise: Accepts slightly slower emergency drop capability for reduced complexity in daily operation
  • Safety Consideration: Relies on the reliability of modern furling systems and luff tapes

This system demonstrates how experienced sailors can deviate from conventional solutions based on specific needs and risk assessment.

Conclusion

Paikea’s mast conversion shows how professional-grade equipment can be successfully adapted for cruising use when approached with clear engineering rationale and practical sailing experience. Every decision—from the large titanium fittings to the simplified rigging—reflects a balance between performance potential, safety requirements, and real-world usability. The result is a rig that delivers America’s Cup-derived performance while remaining manageable for a family crew.

Want to See More of our Carbon Rig?

Explore our videos on how we adapted America’s Cup technology to suit our cruising catamaran.

Leave a Comment

Scroll to Top