Some Things to Consider
A couple of years ago I did some extensive shopping for a new jib at the Pacific Sail Expo. I talked to every sail maker imaginable from the top of the line down to the offshore "internet" sailmaker. The problem with an off market vendor is you just don't know what you are getting in terms of quality. Dacron comes in many different grades as well as weights and can you be sure of getting the appropriate density in the weave? One sailmaker was willing to make me a radial cut jib - in Dacron! Dacron, having the wrong stretch properties was the worst possible material for that kind of sail. Needless to say, it wasn't a confidence builder for the sailmaker not to understand his materials. For that matter will you be getting Dupont Dacron or some other brand? Will your sail have the proper design? I talked to one vendor who made the exact same jib for both a C34 (130%) and a C30 tall rig (155%). I was told that this was a good thing as they could "economize". I know one of us would have had problems passing muster getting a PHRF measurement with that sail. Is the sail designed for your local conditions or is it designed around an "average" cord? A deeply cut jib won't do you much good if you have predominately windy conditions. Will it be constructed well? I wasn't that impressed with the internet company's workmanship. Seams were either single or double stitched when they should have been double and triple stitched. Threads weren't tied off. The reinforcements around the tack, clew and head felt flimsy. This sail was about half the cost of one from a top tier company and to me, was only half as good. I was thankful that he brought that sail to the show and not something that was "dolled up" as I know I would have been disappointed if I went with that maker. I think that pretty much all the national as well as many local sail makers build new sails offshore, utilizing their local lofts for mainly repairs. What you are getting, IMHO, from a domestic sail, is good design work, high standards in construction, good craftsmanship and a company that will stand behind their work So if something goes wrong, they will be there to fix it. My sailmaker has been to the boat several times, sailed with me, made adjustments and even took pictures of the sailshape. With offshore vendors, once that check clears, you are pretty much on your own.I must confess that I am on the performance side of the spectrum. I am willing to spend the extra money for a sail maker to make one custom to my boat's unique measurements. You would be surprised how much variation there is in production boat building. While the basic sail plan measurements are usually pretty close, there can be big differences in things like stay/shroud placement and where the fairlead track is bolted. Having someone throw those measurements into the computer and come up with the right sail is important to me. I would still go domestic if I was looking for a cruising sail, I might go to a second tier type sailmaker to save costs, but I definitely wouldn't go offshore.