Sounds like you've had a busy time.. was wondering how you were making out. Easter weekend was interesting, wasn't it? Were you out on the Sunday?
Don't really have any suggestions for you except to say that most sail insignias these days are vinyl stick-ons. As for sewing, just make sure you have UV resistant thread.
1984 Fast/Nicholson 345 "FastForward"
".. there is much you could do at sea with common sense.. and very little you could do without it.."
Capt G E Ericson (from "The Cruel Sea" by Nicholas Monsarrat)