Hi Bleemus. I wondered about this myself, and was hoping it would be as simple as attaching hanks to the tape by mechanical means or even sewing each one on.
How would you replace the tape with a bolt rope?
Not too good about sewing so yes, it is a serious question.
For a sailmaker it is easy as they have all the equipment on hand.
If you want to do it yourself you will need the following.
A length of boltrope tape purchased from a sailmaker.
Hanks and Hank chafe guards
HEAVY DUTY sewing machine
Grommet punch and grommets.
Awls and vice grips with block and tackle attached to handle
Remove old luff tape with seam ripper
Lay sail out on floor with a fold one foot behind luff and awl head and tack
Awl the head of the sail and top of new luff tape to the floor
Attach vice grips to bottom of luff tape and awl the block and tackle to the floor
Tighten block and tackle and tension the luff tape a lot more than you think
Staple the luff tape every few inches to the sail
Remove all the Awls
Stitch luff tape to sail
Punch holes for grommets and install grommets, chafe guards and then hanks.
Probably forgot a step or two since it has been awhile. Very important that the luff tape goes on the sail with that block tension. You want the majority of load in the tape and boltrope not in the single layers of sail fabric. Only need enough tension in sail to adjust draft position. Nothing more.
Unless you have all this gear you are better off having it done professionally.
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