Precision Racing Upgrade: Carbon Mast & Rigging Overhaul for Beneteau First 40 "Rogan Josh"

The Beneteau First 40 "Rogan Josh" recently underwent a comprehensive carbon mast and rigging refurbishment, carried out between Southampton and Hamble at the Royal Southern Yacht Club. Initially brought to First Spars for minor upgrades by its new owner—an experienced sailor—the project quickly expanded after a full mast, spars, rigging, and hardware inspection revealed critical structural and performance-related issues. To ensure safety and optimize IRC racing potential, an extensive overhaul was undertaken.

Assessment & Key Findings

A thorough inspection identified several major concerns:

• Delaminated reinforcement pads on the carbon mast, compromising its structural integrity and requiring immediate reinforcement.

• Incorrectly assembled rod rigging, posing significant safety risks due to improper tensioning and alignment.

• Severe wear and tear on the running rigging, reducing efficiency and affecting overall sail handling performance.

• Mismatched deck and mast hardware, which was not optimized for competitive racing or efficient performance cruising.

Scope of Work

Mast Inspection & Structural Integrity Assessment

• The carbon mast was unstepped for a comprehensive evaluation.

• Non-Destructive Testing (NDT) was conducted to identify hidden flaws and weaknesses in the carbon structure.

• The mast underwent structural reinforcement to address delamination issues while preserving its lightweight racing characteristics.

Carbon Mast Repairs & Refinishing

• The mast was professionally repaired and refinished using the premium Awlgrip system, enhancing durability and aesthetics while providing long-term UV protection.

Rod Standing Rigging Replacement

• The yacht’s rod standing rigging was replaced with high-performance BSI terminals, ensuring maximum strength, precise load distribution, and enhanced safety.

Running Rigging Replacement

• The running rigging was completely upgraded with performance-focused Southern Ropes and Alpha Ropes, selected for superior handling, durability, and optimal load distribution.

Deck & Mast Hardware Upgrade

• The hardware was completely overhauled with top-tier components from Harken and Antal, improving reliability and efficiency.

• A new Harken Carbo Foil was installed, significantly boosting headsail efficiency for racing.

• The deck chock system was upgraded using the Spartite system, providing a precise and secure mast fit.

• Custom mast sheaves were designed and manufactured in-house, reducing friction and improving longevity.

Challenges & Custom Solutions

Structural Reinforcement

• Delamination in the carbon mast presented a significant challenge. The repair required precision engineering to reinforce the affected areas while maintaining the mast’s lightweight properties.

Performance Optimization

• The previous hardware setup was not optimized for competitive racing. We carefully selected and integrated high-performance components to enhance IRC racing capabilities while ensuring seamless functionality.

Precision Engineering

• Several outdated or suboptimal mast components had to be replaced with custom-fabricated solutions, ensuring a perfect fit and improved performance.

Final Outcome

Following this extensive overhaul, "Rogan Josh" has been transformed into a race-ready machine, fully optimized for high-performance sailing and competitive IRC racing. The combination of structural repairs, advanced rigging upgrades, and precision hardware integration has maximized both speed and reliability.

First Spars' expertise in carbon mast refurbishment, rigging solutions, and hardware optimization was instrumental in delivering a yacht that is now primed for the racecourse, ensuring both safety and peak competitive performance.