Congratulations on purchasing your first XCAT catamaran! However, before you get it out on the water, you'll need to assemble your boat.
Luckily, our simple step-by-step guide is here to help. From preparing your boat parts to the final installation of the boom and controls, we'll walk you through each step so you can hit the water in no time.
Step 1: Preparation
The first step is to prepare thoroughly.
Find a large, clear space and remove all the XCAT catamaran sailing equipment and accessories from their bags, and lay them out neatly.
This will prevent you from searching through everything trying to find the right part and will make the process faster and easier.
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For your first time, set aside around 40 minutes to assemble your XCAT Sail (however, it can take as little as 15 minutes once you know what you're doing!).
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The good news is that no additional tools are required for assembly.
Step 2: Setting Up the Hulls and Crossbars
Next, you need to position the hulls so they are ready for the crossbar insertion:
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On a nice flat surface, lay out the hulls in a parallel position, about six feet apart.
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Position each hull facing outward from the boat’s center.
Once the hulls are in position, take a look at the curved crossbar pieces:
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The front crossbar, known as the "naked bar", has no attachments.
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The rear crossbar includes a motor mount bracket.
Installing the front crossbar
The front crossbar should be installed first:
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Locate the red tabs situated at both ends of the crossbar and flip them into the up position.
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Now, find the forward (front of the boat) insertion holes on your hulls and fit the crossbar one side at a time.
Tip: The XCAT boat hulls have red-printed arrows that indicate the front.
Installing the center bar
Before you install the second crossbar piece, you must fit the center bar. First, identify the front and back ends:
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The end that features the hiking straps goes at the back.
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The front end has a small welded dot on the reinforcement piece.
Fit the front end of the center bar to the front crossbar.
Installing the rear crossbar
Grab your rear crossbar and flip up the red tabs. Then:
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Fit the crossbar piece onto the center bar before you attach it to the hull.
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Once it's attached to the center bar, you can go ahead and insert each end into the hull pieces.
Step 3: Installing the Side Beams and Trampoline
Next, locate the velcro strap found on the center bar and remove it.
Tip: Stow the velcro strap around one of the crossbars so it doesn't get lost. As you move through the setup process, there will be more straps to remove, which can also be affixed to the crossbars.
Unrolling and securing the side beams
Once the strap is removed, you will be able to unroll the side beams. Start with one side:
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Locate the larger attachment points on either end of the side beam and fit them onto the corresponding posts on the crossbar pieces.
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Gently rotate the side beam outwards, and the attachments will automatically snap into place.
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Head to the front end of the side beam and locate the stair-step lock (over the red pin). Press it down to secure it.
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Repeat the process for the second side beam.
Locking the collars
Take a look under one end of a crossbar and you'll see a red collar piece. Make sure that this is snug against the grey hex-part of the hull.
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Rotate the red collar clockwise to secure the beam and repeat the process for all four corners.
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Now, press down on all the red crossbar tabs (those you flipped up earlier) to lock them fully.
Step 4: Setting Up the Running Rigging
Grab the running rigging and lay it out on the trampoline. If the cables are tangled, take some time to straighten them out.
Positioning the running rigging
Start with the Genoa car (the black piece) and fit it onto the center bar. The correct positioning is indicated with two black lines and a "G".
Clip it into place and secure it by turning the screw pin until it sits firmly.
Attaching the side blocks
The side blocks are color-coded green and red for easy installation.
Each side of the trampoline has corresponding colored lines and an "S" symbol that indicates where each block should be fitted.
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Match the red and green lines to the correct blocks.
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Make sure the lines aren't tangled!
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Clip the blocks into place and turn the screw pins to secure them.
Attaching the genoa sheets
Pull out the Genoa sheets toward the front of the XCAT and place them on the ground.
Make sure the red barber-hauler line is correctly positioned under the gray connecting line.
Step 5: Installing the Bowsprit and Jib Furler
Next, pick up the bowsprit piece. Unravel the lines so nothing is tangled.
Mounting the bowsprit
The bowsprit has two wheels and attachment pins:
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Take the wheel end and line it up with the center bar cut out.
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Pull the bowsprit toward the front of the boat so it slides along the center bar.
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When it reaches the end, rotate it downwards so it rests on the crossbar.
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Push it backward (toward the back of the boat) to lock it into place.
Installing the mast step
Take the mast step piece and position it on the center bar cut out. Pull it back toward the front of the boat (like you did for the bowsprit) and it will click into position.
Securing the jib furler
Lift the jib furler and pull it up so it's in the position that it would be for when the sail is mounted:
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Grab the hook on the end of the jib furler and attach it to the Genoa car's shock cord.
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Place the furler lines on either side of the mast step.
Step 6: Preparing the Mast and Genoa Sail
Take the mast pieces, remove the velcro straps, and undo the shock cord. You should also separate and untangle the shrouds to prevent knots during assembly.
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Fit the top and bottom sections of the mast together.
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Lay it flat across the trampoline with the base of the mast facing the front of the XCAT.
Tip: To prevent the mast from rolling away, rest it in the center of the rear crossbar where the rudder would normally be attached.
Attaching the shrouds
Make sure the pad-eye of the mast is facing upwards. Take the shrouds and note the color coding:
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Green shroud (connects to the green side block)
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Red shroud (connects to the red side block)
Secure the shrouds to the corresponding shroud blocks.
Raising the mast and Genoa sail
Before you raise the mast, take the red wind flag and press-fit it into the top of the mast.
Stow the halyard lines to the mast using the hooks and bungees so they're not in the way when you lift.
Then:
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Attach the furled Genoa sail to the mast's pad-eye using the chain link and snap shackle.
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Clip the bottom end of the Genoa sail to the furler drum using the snap shackle and make sure the shrouds are not tangled with the sail.
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Step onto the trampoline, grab the mast in the center, and raise it until it's vertical.
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Fit the base of the mast into the step piece so it stays in place.
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Attach the Genoa sheet by passing the black toggles through the metal ring of the Genoa sail. Remove the velcro sail strap.
Step 7: Installing the Rudder
Before you attach the main sail, it's a good idea to install the rudder. This is attached in a similar way to the bowsprit:
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Set the rudder clip in the rear cutout of the center bar.
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Lower the rudder while simultaneously sliding it back along the center bar.
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Push it so it locks into place.
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Lift the stainless steel handle and place the hook into the slot found in the center bar.
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Push the handle back down until it clicks.
Step 8: Mounting the Mainsail
Lay the mainsail on the starboard side and remove the velcro straps. Then, completely unfurl the sail.
You'll notice there are blue dots situated along one side of the luff. These must be facing upwards (towards the sky):
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Grab the mast from the bottom and lift it up.
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Secure the sail to the mast by looping the sail's luff loops under the lifted mast base. There are five in total.
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Attach the halyard hook to the sail’s head and hoist it up.
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Secure the Dyneema loop into the mast base hook.
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Take the shock cord and attach it to the horn hook at the base of the mast.
Tip: If you prefer a catamaran without the hassle of mounting a sail, our XCAT Row is a good alternative.
Step 9: Installing the Boom and Controls
Just a few more steps and you're done!
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Attach the boom clip to the mast.
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Clip the Cunningham (short rope with carabiner) to the mast.
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Secure the Vang (stainless steel ring) to its attachment point about halfway along the boom.
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Then, attach the main sheet to its designated fitting on the boom.
Tensioning the forestay
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Find the red line connecting the mast to the bowsprit and grab the red knob.
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Pull on the red knob until the furler touches the bowsprit.
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Locate the second red knob and unhook it from the horn on the mast.
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Pull it tight and attach it to its side cleat.
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Tidy up the excess rope by securing it along the mast.
That's it, you're done! Now, you're ready to put your XCAT into action!
Final tips:
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For guidance on rowing on an XCAT, we've got a full walkthrough available.
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Check out our video on how to pack your catamaran away.
Final Thoughts
We hope this guide has demonstrated how easy it is to assemble your new XCAT.
Our small catamaran boats are designed to be simple and quick so you can get out on the water and start enjoying your new watercraft right away.
However, if you have any questions or concerns about the assembly process, please feel free to reach out to us at Red Beard Sailing. We'll be more than happy to guide you.