The Three-Blade Hub is designed to be a direct replacement for the standard two-blade hub and is compatible on all Foil Drive systems except the original Assist.

This article explains how to install the Three-Blade Hub and propellers, correctly fit the propeller bolts, and check that the blades move freely before riding.

Before You Start

You will need:

• Three-Blade Hub
• Three compatible propeller blades
• Propeller bolts
• Foil Drive Hex Driver

The latest Three-Blade Hubs are supplied with CNC-machined 316 stainless steel propeller bolts.

These bolts are stronger than the original mass-produced propeller bolts and feature a shoulder directly beneath the bolt head.

The shoulder is an important part of the design and must fully seat into the propeller mounting hole.

Do not substitute other bolts unless specifically approved by Foil Drive.

Installing the Propellers

1. Inspect the Hub

Before installing the propellers, inspect the hub and make sure:

• The propeller mounting points are clean
• The threaded inserts are seated flush with the hub surface
• There is no sand, salt, debris or damage around the mounting points

The threaded inserts should sit flush with the surface of the injection-moulded hub.

If an insert has been pulled out of position, do not install the propeller until the insert has been correctly reseated.

2. Position the First Propeller

Place the first propeller into one of the three mounting positions on the hub.

Make sure the propeller is correctly oriented and sits flat against the hub.

The propeller should be able to fold freely around its mounting point.

3. Install the Propeller Bolt

Insert the supplied 316 stainless steel propeller bolt through the propeller and into the threaded insert in the hub.

The shoulder beneath the bolt head should locate inside the mounting hole.

Tighten the bolt until the head and shoulder are correctly seated.

Do not overtighten the propeller bolt.

The propeller must be able to move freely on the bolt. The bolt should secure the propeller while still allowing it to fold in and out without binding.

4. Repeat for the Remaining Propellers

Install the remaining two propellers using the same procedure.

Once all three propellers are installed, check that:

• All three propellers move freely
• All three have a similar range of movement
• None of the blades are sticking
• None of the bolt heads are protruding
• The propellers sit correctly against the hub

Check Propeller Movement

This is one of the most important steps before using the Three-Blade Hub.

With the motor switched off, manually move each propeller blade through its range of movement.

Each blade should fold in and flick back out freely.

The three blades should move consistently and without excessive resistance.

If a Blade Is Sticking

A blade that does not move freely can cause the propellers to deploy unevenly.

When the motor starts, a blade that has been stuck can suddenly release and deploy with significant force. This can cause vibration and potentially place excessive load on the propeller hardware.

If a blade is sticking:

1. Check that the propeller bolt has not been overtightened.
2. Loosen the propeller bolt slightly and check the blade again.
3. Check that the threaded insert is sitting flush with the hub.
4. Inspect the area around the blade for any moulding ridge, debris or salt buildup.
5. Rinse the hub thoroughly with fresh water.

Do not ride the system if a propeller blade is sticking or does not move freely.

Using the New 316 Stainless Steel Bolts

The new machined stainless steel bolts feature a smooth shaft and shoulder, rather than the partially threaded shaft used on earlier bolts.

This provides a stronger and more rigid mounting arrangement.

The new bolts also include a small amount of thread-retaining compound.

This helps provide friction to prevent the bolts from loosening during use. It is not intended to permanently lock the bolts into the hub.

Saltwater Maintenance

Unlike the original partially threaded bolts, the smooth shaft of the new bolts does not provide the same pathway for saltwater to flush out of the mounting area.

Salt crystals can therefore accumulate around the bolt and propeller over time.

If a propeller starts feeling stiff, grabby or difficult to fold:

1. Remove the propeller bolt.
2. Thoroughly rinse the hub and propeller with fresh water.
3. Remove any salt or debris from the mounting surfaces.
4. Reinstall the bolt.
5. Check that the propeller moves freely.

Regular fresh-water rinsing is particularly important when riding in saltwater.

Final Pre-Ride Check

Before every session, inspect the Three-Blade Hub and propellers.

Check:

☐ All three propeller bolts are secure
☐ No bolt heads are protruding from the hub
☐ All three propellers move freely
☐ All three propellers deploy evenly
☐ The threaded inserts are seated correctly
☐ There is no sand, salt or debris restricting movement
☐ There is no visible damage to the hub or propellers

If everything checks out, the Three-Blade Hub is ready to ride.

Important

If a propeller is sticking, the hub is damaged, a threaded insert has moved, or a propeller bolt cannot be correctly seated, do not use the system until the issue has been resolved.

00:00 Introduction 

01:02 New Hardware - Introduction 

02:50 Cause and Effect - Hub Damage 

03:33 Solutions - Propeller Bolt Tension 

04:19 Solution - Centre Bolt Tension 

05:35 Solution - Ridge Removal 

06:09 New Hardware Upgrade - Overview 

06:29 Two Blade Hubs - Installation 

07:45 New Hardware - Comparison