My old sail cover was completely beyond repair. The fabric was starting to fail like the knees in an old pair of jeans. So I bought some new sunbrella on Ebay and made a new cover for less than $50.
Chris, You will like the method that I used to fit it. I bought a length of fabric a couple feet longer than the boom and pinned the selveges together after I draped it over the furled sail. Then I pulled the excess fabric up until the pinned selveges were close to the boom and I then pinned the top line. When I had all of the pins in place I removed the pins at the selvege and took the fabric home with the seam line defined by the pins on top. After that it was just a matter of fairing the line and adding seam allowance. By doing it in this manner the excess fabric came off in one piece right out of the middle.
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