How Sails are Made?
GETTING PREPARED
- Sketch out your sails. You may get inspiration from similar boats. Research the dimensions of similar sails and have an idea of what kind of sailing you’d like to do. This gives basic reference points to research and execute.
- Ensure your workspace is large enough for your materials because it may need a lot of room according to the size of your vessel.
- An industrial sewing machine will be needed for zigzag stitching, a special sewing table will also be needed if you planning to sew the sail yourself. For safety and durability, it could be better to outsource this part to local loft.
- Have a clear understanding on the dimensions of your boom and mast because this will affect the correct calculation of the size of your sail.
DESIGNING YOUR SAIL
- Draw the luff curve, also known as the front of the sail. This is the most important part of the sail because it support the integrity of rest of the sails. The top third of the luff curve will be slight and the bottom of the curve, close to the boom, will be greater than the mast curve.
- Putting battens. Add more battens if you are planning to have more stability of your sail, otherwise, less battens can be used for easier control and flexibility. If the pockets for battens to attach to the sail is adjustable, which could allow you to adjust the sail according to wind conditions.
- Adding seams. Seams on your sail can help you to shape the sail easily. It can also help to optimize the amount of material you use. Stiff materials could be used near the bottom of your sail, which will provide the stability and durability of the sail.
- Create a pattern and select the fabric. Heavy monofilm and woven sailcloth are common choices. Monofilm is a cost-effective option but you will need to select sturdy material for the luff and bottom of your sail. Pentex taffeta scrim laminate is endurable but it is relatively costly. Some people would use special polyesters and laminated woven fiber as well.
ASSEMBLING YOUR SAIL
- Outline the edges of the panel and place your pattern onto your chosen material.
- Carefully cut out your pattern, ensure that your shape will be about 35% from the luff when you are creating a seam with shape.
- Stick and sew two panels at a time until the sail is all in one piece. Move from panel to panel while leaving extra cloth at the external edges of the sail.
- Reinforce the seams by tape. You can also add strength by putting glue on a layer of a cloth on either side of the material.
- Strengthen the foot and batten pockets, because these areas will be applied high level of tension, so make sure these parts can withstand the amount of tension.
- Make the sleeve of the mast by measuring the width of existing sail and make adjustment if needed. Sleeves can either be a single piece or made from a number of pieces of material but ensure that the head is reinforced and capable to withstand the strain from the mast tip.
