SPECIFIC AREAS OF REPAIR

Observe how the sail was originally constructed in an area similar to that being seamed. Consider whether the original method of construction needs reinforcement. If so, cover the cloth edge with a piece of adhesive backed Dacron cloth and re-sew. If the thread is worn or sun damaged, it can be re-stitched by machine or by hand.

1. Insure cloth is salt-free and dry.   Treat with alcohol to displace moisture,  if necessary.  Remove old thread pieces.

2. Pin out seam in original shape. Use needle holes, wear pattern, etc. to re-establish the original relationship of cloth edges. If the seam is not split yet, but is in danger of coming apart, FIX IT NOW! To do so, run pencil along seam edge, draw strike-off marks, then pull the seam apart and remove the broken threads.

3. Pin the seam out and put double stick tape on the bottom layer of cloth, pull off paper backer, and lay top cloth in place. When you are sure it is lined up correctly (no ripples in one layer, even tension on both pieces, ends of seams are same lengths as original), press top cloth down firmly smoothing cloth into place.

4. If sewing by hand, sew / / / / /, then back in opposite direction, using original holes, to form a zigzag stitch. This allows the stitch line to stretch with the cloth. If necessary, punch holes through thick areas of cloth with an awl. Use the awl to mark off holes at regular intervals of 1/4" or 3/8" for even stitching. Use appropriately strong thread, doubled if necessary. Pull tension on each stitch as you sew. If sewing by machine, sew seam, using original stitch holes if possible.

5. Cover repairs with adhesive-backed cloth tape if seam is in a high chafe area.

ALWAYS FIX THE SOURCE OF WEAR - Abrasion? Puncture by sharp object? Insufficient reinforcement for strain on sail?  Whatever it is, fix it to prevent further damage.

SMALL HOLES (LESS THAN 4") OR A STRAIGHT TEAR OF 6" OR LESS:

1. Repair small holes in unstressed areas using adhesive Dacron tape or cut cloth.

2. Dry sails as thoroughly as possible, using alcohol to displace moisture. Adhesive does not stick well to damp cloth.

3. Cut two patches of the appropriate size. The patch should extend beyond the hole by 2" to 3" in all directions.

4. Pin the area as flat as possible using thumb tacks, or ask someone to kneel on the area and secure it with his or her hands.

5. Lay the tape on the sail and pin it or hold it in place. Remove the paper backer and press down well. Turn the sail over and apply the other patch in the same place. Rub down firmly.

LARGER HOLES OR TEARS:

1.  Try to separate long jagged tears into a series of straight lines. Most tears run parallel to threads in the cloth.

2.  Pin or flatten area to be repaired. Line up the cloth in its original position. If this is not right, the sail will not be flat. It is worth taking time to get it right. Tape together with masking tape—just enough to keep the edges together while you make the patch.

3.  Draw the patch on the sail. Keep lines parallel or perpendicular to threads in the cloth if possible. Put double stick tape around line. Do not remove paper backer yet. Cut around inside of tape with hot knife or scissors.

4.  Use cloth that is closest in weight to the original sailcloth. Lay it over the hole with the threads aligned the same way as the original cloth. Pin it out flat through the sail.

5.  Draw the outside edge of the tape (you can see the tape through the patch cloth). Unpin patch material, lay it on a flat surface, and cut around line using the hot knife and straight edge. The patch can also be cut with scissors; run the hot knife along the cut edges.

6.  Place patch over hole, align everything, and pin down except for one edge. Remove tape backer from this edge and press down patch. Work around patch until all edges are stuck. Press down well. You can also make strike-off marks in case the patch comes unstuck while you are sewing.

7.  Sew around patch as for seam repair. Use a small needle and a zigzag stitch.

For problems with hardware (slides, webbed rings, etc), try to duplicate original method using hand sewing techniques. Punch holes first with an awl if necessary. Use palm to push needle through cloth and pliers to pull it back through the material. Avoid wiggling the needle to help pull it through the cloth. The needle will break at the eye and/or the thread will chafe.

PRESSED RINGS:
If the fabric is partially intact, first try strapping the existing ring. If that will not work, cut out old ring using the new ring as a pattern. Hot knife edges of cut, tape web straps 7-14" long on each side of sail through the ring, tensioning the webbing, as it will stretch under load. Ring should be snug against the sailcloth when complete. Sew through sail and both layers of webbing using zigzag stitch as above. Make awl holes to allow needle and thread to pass through layers without abrading thread.

BATTENS
        A. Inspect ends for roughness. Sand or cover with end protectors or chafe tape.
        B. Insure batten length matches pocket so that end is in reinforced area.
        C. Tape pocket tears with duct tape minimally until you can repair properly.

SAIL REPAIR KIT SUGGESTIONS