Sunday, February 14, 2016

Cape Dory Typhoon Genoa 3 wrapping it up


Time for the hand sewing.  This is the stitch by stitch stuff that adds real strength to the pressure points on the sail.  For this, sailrite has sent along wax coated Dacron thread and a sail makers needle.  The needle is like a tiny bayonet.  Three sides and super sharp, poking yourself and you're sure to bleed a bit. I use a few other tools when doing this. One of them, is my trusty sewing awl.  This is a must have in my opinion.  I'm sure you could get by with a regular awl, but this thing makes punching through finishing leather, nylon strapping and six layers of Dacron a bit easier.  



I didn't bend the needle,  it came curved.  I suspect this little curve adds some strength or at least takes direct pressure off the shaft of the needle as you jam it into something hard.

This is a thick brass thimble.  Last sail I made I punched right through a little tin one and into my hand. I'm not making that mistake again.  Most of the time I actually stick this on the back of the sail maker needle to help push it through the fabric.

The head and tack has a brass reinforcement rings sewn into the sail corner patches.  First, you have to cut a small hole through the patch then sew all the way around the ring basically in bedding it into the sail.  Then comes the easy part,  you simply lace the eye and luff edge back to the brass ring.  This will stiffen up the whole head structure significantly.  


To cover up all the structural work of the lacing, I dress up the outer layer of the corners with some white pearl leather.  This again, adds another layer of strength to the corners of the sail.



Here, you can see the final product for the Genoa's head.


Here is the tack, basically the same process as the head. In-bed the brass ring and wrap waxed Dacron through and around.  


The tack finished and wrapped in its leather outer casing.


The clew is a little different.  The hand stitching goes around the outer edge of the ring through all that nylon strapping and the thickest layer of the Dacron patch.  The sewing awl is your friend here.

Here is the tack finally wrapped up with a butterfly cut piece of leather passed through the ring for additional support.  

The last thing to do was press on the grommets and sail hanks.  Thankfully sailrite sent extra grommets I messed up three of those buggers before I got a hang of using the grommet press tool.

My previous sail came with nylon clip on hanks.  Frankly they are a pain in the neck and it's not unusual for one or two of the lower ones to come unclipped when raising the sail.  I opted to go with brass hanks for this sail and now that I know how to use the grommet tool I for see changing out the nylon ones on the working jib in the near future.   (There is always another boat project.)


One completed Genoa.


I even installed the new sailrite logos. This was a tough decision I actually have two of the older logos in a box that I almost stuck on, so they would match my other sails but ultimately decided I liked the new logo more.  The only thing left to do now is install the tell tails but that will have to wait until spring when I set the sail up for the first time and get a real sense of where exactly on the sail I want them placed.


Here we are, folded up and waiting for spring to break.  It is 8 degrees outside right now.  Brrrr.

















5 comments:

  1. I am very impressed by your work Chris. Cold weather has great effects on you! You're truly personalizing your vessel in a special way. Plus, you have in-depth knowledge of whats on your vessel this way. I guess it's an aquired taste. I admire your work but will not be crafting any sails for mine yet, lol. Beyond my skill set!

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    1. Thanks William I have to keep busy warm or cold. The sail really was not difficult to put together it just takes a bit of patients. I'm sure it will pretty not last as long as a sail sewn by a lift but it is probably half the price. Thanks for the numbers on the rigging by the way.

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    2. Thanks William I have to keep busy warm or cold. The sail really was not difficult to put together it just takes a bit of patients. I'm sure it will pretty not last as long as a sail sewn by a lift but it is probably half the price. Thanks for the numbers on the rigging by the way.

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  2. Congrats on wrapping up the genoa project. In addition to the Speedy Stitcher sewing awl you have, you might invest in a sailor's palm to keep in your ditty bag - along with some waxed twine, patch material, and hand-sewing needles. Sailrite is one supplier of the palm: http://www.sailrite.com/Palm-Adjustable-Right-Hand
    I used one of these adjustable palms for a bit before buying a high-quality fitted palm. I wouldn't try sewing without it. You might also add a good pair of pliers to your ditty bag to help pull the hand-sewing needle through heavy assemblies. http://ariel-cd36.org/wordpress/?p=504

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    1. The sailors palm would sure be nice. Thanks for the suggestion. I think it will likely be a while before I'm sewing any new sails again. I've got a hole new suit now!

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