Recutting your own sail?

[Jim Haynie]

The sails on my 1988 Legend 37 are still good and strong but badly bagged out. I know that recutting was once common, but the lofts I have contacted have little interest in doing it because they can make so much more money so much faster by selling me new ones. But, I have a friend who runs an awning shop and I've used industrial sewing machines (including heavy-duty walking foot zigzag) for lots of upholstry work. I believe that I (working with my friend) could do the work if I could get good information about how much to take up and where to take it. Would it be some improvement to simply cut about 3/8" out of every other horizontal seam on the main? I'm not expecting miracles or race course performance, but if I could make the sails a little better for about 5 more years, then I might be able to afford a new set. Seems to me that if I took about 3/8" out of the most baggy portion of several seams and taper to the existing positions on both ends of each of those seams, it will be an improvement. Could start by doing 3-4 of them and see if it helps by examininng shape under sail, then decide whether to do more?? What think ye? Will I just ruin them by trying this? THANX, jim

 

[Bill O'Donovan]

Tricky stuff

The problem is that if you're just a little bit off, you're screwed. As with building stairs, there is no margin for error.I had my sails recut last winter by Hayes Customsails in Hayes VA and recommend them highly. Been going there for years. He showed me what he did and how he did it, and believe me you do not want to do this trial-by-error. Email me at bodonovan@vagazette.com and I'll get you more details.

 

[Ron]

Wellll

There is a lot more than what you are saying to re-cutting sails, but I give you a thumbs up for wanting to do it yourself. Give Jim Grant at Sairite (Sailrite.com) a call and see what he thinks. He is a very nice guy and will help you a lot. He can also give you a price quote on a sail kit that you can put together yourself for a whole lot less than buying a ready made sail. You have the equipment so you are halfway there. I do all my own sewing work and also for others. It is not hard, just takes time and patients. Hope it all works out for you... Ron/KA5HZV

 

[Ken Gehrels]

a trial "recut"

Bravo for thinking of trying.I've got a set of really bagged out ol' stinkers. No loft wanted to touch them. Recommended I use them for painting drop sheets. Couldn't afford new ones. One source suggested that instead of a full recut, to simply try sewing in a tuck. That way, if you mess up (which you probably will first time round) you can pull the thread out and be none the worse for wear. We did that on genoa and main. Took a couple of trys before we were satisfied, but seems OK. Works way better. A little tuck certain has large influence. Don't overdo it. Be careful to not have any large shifts - GRADUAL tapers at end - in order to limit puckering and tight spots.Good luck!

 

[MArk]

Pleating

If you pleat rather than tighten seams, remember the "Pleat Formula":1. The full width of the pleat should continue at least over a distance equal in feet to the number of quarter inches of the pleat.2. The taper at each end should run for as near to a quarter of pleat width as possible.Example: For a 1" (4 quarter inches) pleat the pleat width should be at least 4 feet and the taper at each end should be an additional 12 inches.If you tighten seams, mark the sail before unpicking and use double-sided sticky tape to keep the panels aligned during sewing. Pull the tape out as you sew.The very best book on sail making, examining, repair and alteration in my library is "The care and repair of sails" 1976 by Jeremy Howard-Williams, Sail Pubns/Norton Distr; ASIN: 0914814060. It's out of print but you can get a used copy through Amazon or others really cheap.Happy sails,MArk