Materials and Lofting
The original material would have been a heavy calico, which
was impregnated with a ’paste’ to wind-proof it.
We decided on 2’ wide white lightweight Duradon®
(from British
Millrain), a dense synthetic sailcloth that closely resembles
canvas in appearance and performance. The material lasts better
as it does not rot when stored wet. The thread used is V69
Polyester and the lines and rope are 8mm and 6mm Cousin/Marlow
Polyhemp, again a traditional-looking Polyester material that
lasts well.
The triangular jib measures 4’6”
in the foot, 8’6” leech and 9’6” luff,
three panels are needed. It is roped with 8mm polyhemp on
foot and luff. The boltrope is rat-tailed (thinned and tapered
out at the ends) and forms clew, tack and head cringles, which
are seized and served with 2mm marling twine.
The mainsail is a high peaked spritsail of 9’ luff,
12’ foot, 9’ head and 15’ leech. It is again
boltroped with the exception of the leech. There is slight
broad-seaming used to give the sail some shape or camber and
for the same reason leech and head are hollow, while the foot
is slightly curved outwards. Again, the boltrope is rat-tailed
and forms clew, tack, and throat cringles, which are seized
and served with 2mm marling twine. The beckit, which takes
the sprit at the peak, is treated the same way. The 17’
sprit is 2 1⁄4” knot-free spruce, tapered to 1
1⁄2” at the ends and a shoulder at the peak end
in which the beckit rests. The snotter, holding the sprit
at the bottom, is a twisted 12mm rope grommet.
The grommet is made from a length of rope
three times the diameter of the grommet. The three strands
are separated and one strand is then used. A circle is formed
in the middle of it and one end at the time is then laid back
into the circle, following the natural twist of the rope.
The ends are then heat-fused.
Back to Top of
Page
Making the Sails
We scaled up the sails from archive photos (Sailplan)
and marked out the dimensions on a large floor area with chalk.
The cloth is then laid out on the floor, parallel to the leech
(minimising strech), allowing extra material for the hems
or tabling in nautical terms. The panels are then stuck together
with double-sided tape, giving a 1” seam and sewn with
two rows of cross-stitching at each panel. This was done on
an industrial Singer
107-W1, “the workhorse of the industry”. Next
the sails are laid out again and the dimensions plus the tabling
(1 3/4” at the luff and 3⁄4” everywhere
else) marked on the sail, including any hollows and curves.
The Duradon material is then cut with a hot-knife, which cuts
and seals at the material at the same time. Again double-sided
tape is applied to all the tabling which is then turned and
stuck on. On one of the sails, the boltrope runs through a
pocket forms by the seams. It exits the pocket c. 8”
before the corners, where it is sewn on. Then the tabling
is sewn-on with cross-stitch. For the pocketed suit, 5 of
No. 2 eyelets in the tabling will hold the luff to the mast.
The Rigging
The 12’ long and 4” diameter un-stayed mast is
squared at the bottom, where it meets the mast shoe. The top
18” are tapered to 2 1⁄2”. The bowsprit
is tapered from 3” to 2 1⁄4” over 5’
length. It is checked-out where it is held with rope to a
block in front of the mast. It exits through a steel ring
on the stem. The sails are attached to mast and bowsprit with
8mm polyhemp rope through holes in the mast. A looped 6mm
rope holds the mainsail to the mast.
Back to Top of
Page
Suppliers
Sailcloth is supplied by British
Millrain and all fittings, and double-sided tape can be
got from Kayospruce
Ltd. Most chandleries should be able to supply polyhemp
rope. See Links for details.
Materials List
Per suit of one jib and one mainsail:
75' of Light Duradon white sailcloth, 24” wide
V69 white polyester twine
1 roll of 3⁄4” double-sided sail tape
45ft of 8mm polyhemp for bolt rope
25ft of 8mm polyhemp for rigging
18ft of 6mm polyhemp for lacing
1 roll of fine marling twine
1 roll of sail-making thread for hand sewing
Back to Top of
Page |
|
