Info Sources For Re-Cutting Sails

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Jun 21, 2007
2,118
Hunter Cherubini 36_80-82 Sausalito / San Francisco Bay
I thought to post this on both the Sail Trim and Ask All Sailors:

I would like to know where I can find information about how to re-cut an older sail. Not so much techniques for doing stuff like the actual stitching, reinforcing, webbing, etc. But how to determine the improved shape.

In my case it's for an older 7 or 8 ounce'ish Dacron ~95% jib . The sail's overall condition is good for several more years, but it doesn't have enough life left to support a sail loft's charge for the work. (My time is free as the comparing benchmark!)

I recently hoisted an almost new head sail that I encountered for a song. With my split backstay tensioner also cranked down to tighten the head stay, the pointing ability of my boat was very noticeably improved. The tell tails continued to point back I would say at least five degrees more into the wind than with the older 95%'er. Problem is that this newer sail equates to maybe a 75% jib. OK for the frequent 25kt+ winds in San Francisco Bay's slot. But too small for general use.

My thought on re-cutting the ~95% sail is to keep it minimal and in line with my abilities. Cut the threads and remove the #6 luff tape. Cut away some of the sail's luff in an arc. Re-attach the #6 luff tape. The forward section of the sail will be flatter with more forward draft. Boat will point better. It's the amount to cut away that I would like to have some guidance about.

Thanks for the input.
 
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RichH

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Feb 14, 2005
4,773
Tayana 37 cutter; I20/M20 SCOWS Worton Creek, MD
First of all 90% of the 'shape' of a boltroped dacron sail is due to the precise length of the boltrope ... and boltropes 'shrink' overtime due to constant stretching relaxing.

If you KNOW the exact 'as built' / new dimension of the luff boltrope (and foot if also boltroped) then its EASY to DIY restore the shape in a dacron sail.
To test/evaluate if a shrunken boltrope is the cause of an 'out of shape' or 'baggy' older dacron sail, go to: http://forums.sbo.sailboatowners.com/showthread.php?t=120970 and scan down until you find "shrunken boltropes". With 'standard database' sailmaker's dimensions you can 'easily' adjust or 'ease' that boltrope back to 'proper' or as-designed length or you can adjust the flattness or amount of draft - simply by adjust that boltrope.

The biggest problem with virtually ALL dacron sails is that most people do not properly raise and then 'stretch them out to their 'design' dimensions.
And if there is a shape problem, probably 99% of all 'heavy used' boltroped woven dacron sails can be 'brought back from the dead' with a DIY (or sailmaker) boltrope adjustment. All those 'hints' are in that above 'article'.

On my racing boat(s) I readjust that damn boltrope about every 150 HOURS of hard use ... and 99% of the time thats enough to restore the sails SHAPE
 

LeeBob

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Mar 20, 2010
10
Odayowners 272 le Puget sound
Turns out I am in the same situation as rardiH36 and I thought the topic was re-cutting sails. My genoa flaps so hard I don't think I need any wind. Should I un stitch it and lay it purfictally flat? Or do I need some sort of shape?
 

RichH

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Feb 14, 2005
4,773
Tayana 37 cutter; I20/M20 SCOWS Worton Creek, MD
The 'best' is to have a sailmaker go along for a ride in moderate condition ... both to show how to 'shape' a sail and to make recommendation for any 'recut' if needed. An experienced 'racing sailor' would be the next best, followed by a good set of pictures of the sail being flown in moderate conditions (usually when close hauled) - the best pics would be taken from on the boat and from another boat at a moderate distance away.

Got pics that you can post?
 
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