New mainsail question

[Robin]

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We did the original measuring off the old mainsail which fitted like a glove, we went back and rechecked our calculations which were spot on.

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I think the explanation lies here I'm afraid. The sailmaker has very probably allowed for the fact that you are measuring an old sail which a) will not be held taught by the halyard and outhaul so that you can measure it accurately and b) will have been stretched after years of use. The sailmaker has to make a judgement call on the dimensions supplied, too big and it definitely won't fit the spars, too small will still work.

Much better would be to measure the spars (haul a tape, and not a cheapo stretchy one, on the halyard for the luff measurement) or to rely on the sailplan the sailmaker will have on file.

 

[FAITIRA]

My sympathy, I am in France now waiting for new sails to be "redelivered", having had to leave Ireland with the old ones.
As required by the sailmaker, the max dimentions of the spars were supplied to him, then he allows for stretch and hardware.
Sadly they made no allowance for anything, so the sails are a very nice job, but, to big.
Sails returned at their expence, up to now they have admitted the fault is theirs.
However we are now stuck in France waiting for them to be returned to an address here.
Frustrating, the good news is the weather is not great and we are enjoying staying with family in Brittany.
I think you should get them put right now to avoid more complicated negotiations later.