Build or Buy a New Mainsail

[Sabreman]

I'm in a real quandary - to build a new mainsail using a Sailrite kit or to buy one for roughly twice the cost. A third option is to buy a nearly new one from one of the used sail brokers.

I have a Sailrite machine (the blue one) that I used to make all of my interior cushions, dress canvas (sailcover, wheel cover, etc.), some sail repairs, and other canvas projects. I plan to put a new luff tape on the used genoa that I just purchased. Now I'm thinking of tackling the Mt. Everest of canvas work, a new main. I'm comfortable sewing and if this was a smal sail, no problem. But this is a BIG job (Luff: 43.5', Foot: 13.5'). I have a location to build the sail (my conference room or a customer's conference room), where I can set up for an extended period, so that's covered.

My current sail is 24 years old and should be replaced even though the PO seems to have had it retrofitted by North for full battens. I'd like something with a more full roach and 2 sets of reefs. While we can afford a new sail, the Admiral would be much happier with the Sailrite cost (~$1500) and the challenge would appeal to me.

Has anyone built a sail of this size? Opinions? I'm looking for Sailnet-ers to kick me over the edge on this.... you're so good at kicking the life out of a topic!

[GaryHLucas]

If I had the sewing machine, the space, and already had some experience sewing I know I'd give it a try. Or if I was really worried about my skills I'd tackle a smaller simpler sail first. Maybe for your dinghy!

[winterbuoy]

Do it, I have the same machine. Should be no problem with it. If you've already done all that, how hard could a sail be? I'll be doing repairs on our sails at some point and that's why we bought the zig zag model in the first place.

[CrazyRu]

There is another option - skip sailrite kit and make your own sail for 1/4 of a cost.
Sailcut CAD software is quite good and free
Main Page - Sailcut

To answer your question - I didn't tackle project this big, I did a few smaller sails. However, you have all neccesary ingredients for big job, you will never know where your limit is unless you try to reach it, right?

[Sabreman]

Crazy - I was planning on a Sailrite kit (~$1500) but Sailcut is interesting although I worry that I'd have to cut the material myself. My biggest worry was sewing the batten pockets. It will not be feasible to roll the head or foot enough to stuff under the machine's arm - there is too much material. When I restitched the sunbrella on my genoa last month, I had to stitch in from the leech about a foot. That wasn't too bad once I realized that I don't have to roll the entire head or foot.

Thanks for the suggestions and encouragement.

[tommays]

Having made a J24 spinnaker that worked out pretty good IT was a LOT of work.

Your going to have to at least have the various outhaul and reef point eyes ect pressed in as anything you can whack in by hand will not be strong enough for a sail this size.

The next time i would look for a good used sail the right size or close enough and the do some minor repairs

[CharlieCobra]

The biggest issue with sail making is having the lofting space. I'd love to make my own sails but I don't have the machine or the floor space to do the job.

[RobertKWFL]

As an inveterate do-it-yourselfer, I'm intrigued by the idea of designing and building my own sails. I've enjoyed doing all of the custom canvas work (cushions, sail covers, etc.) on my 36' boat. What is the practical limit on sail size with a machine like the Sailrite LSZ? What about with a bigger long-arm machine? Are there any other good resources (books, etc.) out there for someone interested in getting into sailmaking? Besides being a huge amount of work, are there serious pitfalls that I should be aware of?

[Sanduskysailor]

Plan C might be to contact an independent sailmaker to design and cut the panels for your sail. Then you could sew and finish the sail yourself. You might try calling Dieball Sails, Somerset Sails, or Ullman Skelly for this approach. Chances are you will get a better designed sail and save some money.

[tommays]

I bought the Sailrite kits complete package of paper back books (5) books







You may not need North sails size but a 38' boat mainsail is really BIG and all the lofts work on wood floors so the sail will slide around

I do think you will need to work with the machine on the floor due to the weight of the sail