Any sailmaker out there - need help on conversion to furling

[Quickstep192]

I'm hoping to convert a sail from hanks to furling and I'm wondering what gets removed before sewing on the roller furling luff tape. The current sail has grommets at the head and tack and what feels like a rope or wire at the luff. I'm assuming that rope is what bears the tension when it's hoisted in hanked on mode. I know (think) the grommets get cut off and replaced by webbing, but now I'm wondering about the rope or wire. Does that rope get removed also? If so, what's carrying the tension when the sail is hoisted in the furler? Any help/instruction is greatly appreciated.

[sailingfool]

On my sails, the sailmaker cut off the luff rope and replaced it with a cloth strip several inches wide, with the platic tape along its edge. I expect that cloth/tape takes the load.

[Liquorice]

It's a little bit more complicated than just cutting a bit off and sewing a bit on!
How big is your boat / sail? Most sailmakers will do it for about $150 for a 25ft to 30ft boat.
You have to shorten the sail because the furling drum takes up about a foot at the bottom of the forestay. A little more complicated than just cutting a foot off the bottom.
Give me a bit more information and I'll write a bit more tomorrow.

sam :-)

[Quickstep192]

My boat is 24'; the luff of the sail is 27'; the foot is 10'. I have another sail that's already a furling sail and the luff lengths are the same, so if I cut off the grommets and replace with webbing, I should be OK on the length of the luff. This is just going to be a winter sail, so if it's not perfect, that's OK. I'm planning to take it off each time, so I won't bother with a sun cover. I have the machine and most of the materials. I figure for $60 worth of luff tape and some webbing I get an extra sail and save some bucks. Plus, I can't find a sailmaker around here that will do it for less than $200.

[Liquorice]

In that case, cut just to the sail side of the luff hem all the way up the sail. If you have a hot knife or small soldering iron that's even better as it will seal the edge as you cut. That should take off the two grommets at head and tack plus the luff rope/wire.

The new luff tape should now be positioned either side of the cut sail and pushed in until the sail is fully into the hem and butting against the first (small) rope. Start at one end. Use a stapler and try to tension the luff tape and sail equally. (Don't stretch it, but just tension until the wrinkles are out, so that when let go, the sail and the luff tape lay flat without wrinkles) Use a stapler all along the luff tape to keep it together. Put the staples to one side so you can stitch along the tape without having to stop to take out every staple. Leave a little sticking out at either end of the sail.

Now run 2 rows of zig-zag stiching all along the luff. If your machine doesn't do zig-zag, straight stiches will do - as big as possible (smaller stiches will tend to pucker). Use UV protected polyester thread - V69 or V92 (you can buy it from Sailrite - do a search) Take out all the staples.

Cut the luff tape to length at either end to fit the sail. Have a look at the furling sail on the next dock, or a friends if you have any:-) Notice that the luff tape has been cut back at either end to accommodate the furling gear. About 8" at the tack and about 3" at the head. Copy that.

Use webbing - nylon or polyester to make a loop at the head and tack. Use enough to have about 8inches either side of the sail to sew. Sew through the luff tape and the sail. Run 2 rows of zig-zag or a box pattern with an x in the middle if using straight stitches.

That's it. It's quite an easy and quick job. I like doing them as I feel it's good money for the time taken.

sam :-)

[Quickstep192]

Sam,

Thanks for the superbly excellent instructions. That is exactly what I needed. It makes perfect sense now.