DIY Sail making

[Aeolus]

Just wondered if anyone had ever tried making their own sails. I was wondering about it as I need a new furling genoa (for a 30' bermuda rigged boat). It would be challenging space-wise as I'd need to feed a large expanse of cloth through my reasonably heavy-duty sewing machine but assuming I could manage that (by tightly rolling the already sewn panels)....

I realise that professionally cut sail panels have shape profile built into them but presumably, in the past, sails were made flat and worked pretty well.

Possibly a daft idea but might be fun to try. Any thoughts?

 

[AntarcticPilot]

There is an OpenSource program for designing sails called SailCad. That might be helpful. But I think you'll a) find that you don't save much after you've bought all the consumables and fabric and b) that the lasercutting systems, appropriate equipment, skill and experience of sailmakers do a better job!

 

[Aeolus]

There is an OpenSource program for designing sails called SailCad. That might be helpful. But I think you'll a) find that you don't save much after you've bought all the consumables and fabric and b) that the lasercutting systems, appropriate equipment, skill and experience of sailmakers do a better job!

Of course a professional should do a better job (altho some have been known to cock it up). But that's true of pretty much everything to do with sailing - so maybe we should shut down the PBO forum.

 

[wallacebob]

Sailrite based their business on home sewn sails. They do kits for popular boats, even European , despite being USA based. They are probably uncompetitive now due to import taxes, but their YouTube tutorials can be very helpful. Sailcloth is widely available from UK suppliers. BUT anything more than a make-do sail for an old small boat may be a waste of time, money and effort. People do make usable sails from cheap tarps though!

 

[Blueboatman]

I have cut down a mainsail in the past from a 33 to fit a 28 but that was relatively straightforward as the belly and shape were unchanged..
You’re just recutting the foot and adding new clew and tack with reinforcements. I made it loose footed and it was a pretty good sail for cruising the tropics at the time!

To get adequate draft into a GENOA and cut for the panels layout and clew loading, now that is a different level and if it’s wrong then what?

Oh and it’s a furler too with padded luff

 

[Wansworth]

Just wondered if anyone had ever tried making their own sails. I was wondering about it as I need a new furling genoa (for a 30' bermuda rigged boat). It would be challenging space-wise as I'd need to feed a large expanse of cloth through my reasonably heavy-duty sewing machine but assuming I could manage that (by tightly rolling the already sewn panels)....

I realise that professionally cut sail panels have shape profile built into them but presumably, in the past, sails were made flat and worked pretty well.

Possibly a daft idea but might be fun to try. Any thoughts?

When I converted my schooner to sloop there a was a minor problem with balance so I made a mizzenmast mast and sewed up a mizzenmast sail.My machine does zig zag,a question of cutting the cloth the right way etc there is a book by Bowker and Bud,a slim volume on making sails

 

[Blueboatman]

When I converted my schooner to sloop there a was a minor problem with balance so I made a mizzenmast mast and sewed up a mizzenmast sail.My machine does zig zag,a question of cutting the cloth the right way etc there is a book by Bowker and Bud,a slim volume on making sails

You know that that Bowkers brother was Glen @ Paynes don’t you ?

 

[Little Tern]

Sailmaking can be fun and rewarding.
I have sewn sacrificial strip onto a genoa - easy, though you need a powerful machine
And I've made sails from scratch - but those were junk rigged, and even with cambered panels, much simpler than a Bermudian genoa.
Starting straight in with a genoa sounds... ambitious to me. I don't think a flat-cut genoa would work; you would need to give it some shape.
I think my advice is, yes it can be done, but there's quite a learning curve. And a simpler project might more sense to start.

 

[dunedin]

Making from scratch with new sailcloth is likely to be very hard work - and probably very poor value for money as sailshape poor and usable lifespan less than a professionally made sail.
But second hand sails are generally very cheap, so as others have suggested start by adapting an existing “pre-loved” sail - massively cheaper and less work.

 

[Wansworth]

You know that that Bowkers brother was Glen @ Paynes don’t you ?

No I arrived after Glen had passed away

 

[Blueboatman]

No I arrived after Glen had passed away

Ah. Okdoke . I was lucky enough to get to know him a little. And his nephew who took over the yard (?) had worked for Newbridge yachts at some point iirc knew everything that was wrong with Corribees
Anyways, sailmaking. I have a Sailrite zigzag but no way would I contemplate building a headsail nowadays..

 

[Wansworth]

Ah. Okdoke . I was lucky enough to get to know him a little. And his nephew who took over the yard (?) had worked for Newbridge yachts at some point iirc knew everything that was wrong with Corribees
Anyways, sailmaking. I have a Sailrite zigzag but no way would I contemplate building a headsail nowadays..

Yes I know Mark and have done my bit of yard maintenance

 

[DanTribe]

Just wondered if anyone had ever tried making their own sails. I was wondering about it as I need a new furling genoa (for a 30' bermuda rigged boat). It would be challenging space-wise as I'd need to feed a large expanse of cloth through my reasonably heavy-duty sewing machine but assuming I could manage that (by tightly rolling the already sewn panels)....

I realise that professionally cut sail panels have shape profile built into them but presumably, in the past, sails were made flat and worked pretty well.

Possibly a daft idea but might be fun to try. Any thoughts?

I suspect that your 4th or 5th attempt would start to approach an almost acceptable standard.

 

[Puffin10032]

When I converted my schooner to sloop there a was a minor problem with balance so I made a mizzenmast mast and sewed up a mizzenmast sail.My machine does zig zag,a question of cutting the cloth the right way etc there is a book by Bowker and Bud,a slim volume on making sails

I used that book to make my first spinnaker which turned out OK (although it nearly drove mother insane trying to sew it together - there was no such thing as seam stick in those days. It's not a good book for dacron mainsails or headsails though as they require quite a lot of broadseaming (it doesn't even give a hint of how much broadseaming to use). The Sailmaker's Apprentice is much better although that is also very old.

 

[Puffin10032]

Just wondered if anyone had ever tried making their own sails. I was wondering about it as I need a new furling genoa (for a 30' bermuda rigged boat). It would be challenging space-wise as I'd need to feed a large expanse of cloth through my reasonably heavy-duty sewing machine but assuming I could manage that (by tightly rolling the already sewn panels)....

I realise that professionally cut sail panels have shape profile built into them but presumably, in the past, sails were made flat and worked pretty well.

Possibly a daft idea but might be fun to try. Any thoughts?

Well I suppose I'm a bit of a cheat because I worked as a sailmaker for a few years in my youth and still make the occasional sails for my dinghy (far more than she needs if truth be told).

A Sailrite kit would probably be your best option assuming there are no export/import issues ATM. If that proves a no-go then Bainbridge do offer a sail design service (I think it's something like £60 + VAT per sail) and will also cut the panels for you for a small fee. You problem then would be things like luff tapes and grommets. Luff tapes and slit tapes tend to only be sold in 100 metre rolls, grommets often in a minimum quantity of 100. So you may end up buying far more than you need. You might find a sailmaker who'll sell you just the bits you need but I can't guarantee that.

As for sewing the sail together, rolling the panels to get them through the machine is the easy bit. It's sewing the patches on which is really going to test the machine due to the thickness and bulk, especially on the clew patch. You'll need to use a V92 thread (many domestic machines will take that) and a No 20 needle which do exist for domestic machines but take a bit of sourcing.

I recommend you watch Sailrite's YouTube series about building one of their genoa kits as it will give you a really good idea about the process and tools needed.

 

[KevinV]

Just wondered if anyone had ever tried making their own sails. I was wondering about it as I need a new furling genoa (for a 30' bermuda rigged boat). It would be challenging space-wise as I'd need to feed a large expanse of cloth through my reasonably heavy-duty sewing machine but assuming I could manage that (by tightly rolling the already sewn panels)....

I realise that professionally cut sail panels have shape profile built into them but presumably, in the past, sails were made flat and worked pretty well.

Possibly a daft idea but might be fun to try. Any thoughts?

A furling genoa has to be one of the most difficult sails get right - for it to work reasonably in its various states. I admire your ambition but are you sure you don't want to try something simpler first??

 

[AntarcticPilot]

Of course a professional should do a better job (altho some have been known to cock it up). But that's true of pretty much everything to do with sailing - so maybe we should shut down the PBO forum.

Horses for courses. Plenty of DIY jobs where you can save money and produce a result as good (or better) than commercial offerings. But sailmaking probably isn't one of them, because professional equipment is well beyond amateur budgets.

 

[William_H]

I understand the cost of a new sail is like 50% for material (bought in bulk by a sail maker) and 50% labour to build it. Which would put you at a 50% cost saving or less.
A sail for that sized boat is going to be heavy material and hard to sew. Especially corner reinforcing. Not to mention needing special dollies for eyelets etc. So no not a good idea.
However for smaller boats, dinghies etc I have had a great deal o pleasure making sails especially out of old sail cloth with a domestic sewing machine. The science of angling the warp and weft to give stretch and so camber is very interesting. Do some research. ol'will

 

[garymalmgren]

Just wondered if anyone had ever tried making their own sails.
Dominic did,

 

[ducked]

No knowledge or experience, but I wonder if storm sails (IF one wanted some) would be suitable as a DIY project, since they are relatively small and I'm guessing are cut fairly flat.

OTOH I suppose they are heavier material, which may not be sewable with the available kit.