Originally Posted by Jeff_H
I concur with most of what has been said with a couple additional side notes.
-I typically have my sail covers cut with perhaps 3-4 extra inches on the skirt so that there is better ventilation for those days when you have not choice but to ride hard and put it away wet.
-I typically have a patch of the mesh used for trampolines on multihulls stitched into the inside of the sail cover at the top of the 'boot' so the headboard does not chafe through the sail cover cloth.
-I typically have a flap stitched between the zipper and the mast so the mast and zipper do not abrade against each other, and a second flap that velcro's over the zipper so that the zipper does not UV degrade. (I used to need to replace the zippers every 3 years or so.)
-The sail cover minimally needs to be 4-6 inches short of the length of your boom so you have room to stretch it tight so it sheds rain.
- I like to have a seam that runs the length of the top of the sail cover where the majority of stress occurs.
That's how the sail cover was made for my boat. Whoever made it was a pro. All good points, especially the mesh underside of the boot to absorb abrasion. I don't have an exterior flap over the zipper. Just ripped out the degraded zipper yesterday, waiting for one to come in the mail to replace it:-)
Another handy feature is a Velcro lined heavy canvas wrap at the top of the boot so you can quickly get it set and tied around the mast. It makes it easier to secure when the wind is blowing hard and you need three hands to stop the whole thing from blowing over the side.