Saturday, January 23, 2016

Cape Dory Typhoon Genoa part 2

I've been chugging away on the Genoa project bit by bit here.  So I'm throwing up some more photos of the project.


Corner reinforcement patches. Equal lots of layers.

I use my basting tape sparingly, placing it so it is some what off center.  This way I will not have to sew through it.  I figure 4 or five layers of tape could really add up and I don't need any more layers to sew through.  Each corner's vertex is six layers of Dacron thick. 

Once I got all the layers on, I drew some light lines on the top patch so I could see where to sew.  This will secure the whole patch.



The clew is one of the most complicated assembly's.  To start, I cut and melt the nylon strapping to the right size.


The clew will have a steel ring embedded into the corner.  The first step is to cut out a space for the ring.  I recommend sharp scissors.  See earlier (6 layers). It actually cuts pretty easily.

The next thing I do is lay out my straps and bast them into place along the foot and leach of the sail.

Next I sew them on along the edges.


Then I place the ring in and bast and sew the rest of it down.


These straps are covered by the last layer of the patch. 


The edge straps will be covered by the final taped edge as well as a leather wrap.

The leach finished edge is a 1.5 inch creased piece of Dacron cloth.  It is a three part process to attach it.  First basting tape, then sew it to the edge and finally go back down and sew down the inner edges.  Oh yeah and don't sew on the leach line that you have embedded between the layers.  

One run is equal to one bobbin so after the first run I let the sewing machine cool down before reloading and running down the edge again.

I hand sewed on the gransegel cleat for the leach line. 

Genoa part 3.  Coming soon.








Monday, January 18, 2016

Cape Dory Typhoon Genoa Project

Today, I started sewing up a new Genoa for Kraken.  This summer, I patched and taped the old Genoa several times.  It is ripping down the luff seam, the foot seam and it is pretty thin in several other spots so it is well past time for the old sail to be retired.  I believe the Genoa may have come with the boat in 1978.  Happy birthday to me and the boat; at 38 years, we are the same age.  This is my second sailrite sail. A few years ago, I built a working jib. Here's a link to that project.  The previous owner built a main and a storm.  So this will fill out the sail inventory with all sailrite sails.  

Over the last few weeks I've been working on getting a sewing machine fixed and tuned up.  It has been interesting as I have pulled apart and checked the timing on my machine. I even made a few modifications to beef it up a bit and allow for some extra clearance at the base plate.

 Friday the kit from sailrite arrived! This was super fast I did not expect it to even ship until Friday and here it was delivered by UPS.  Can't knock that the guys and gals over at sailrite got this one out super quickly.  Special thanks to Jeff Frank who ran all the numbers and answered my questions.

Today I started laying out the pieces and parts for an inventory. I wasn't going to start until; well it is... 10 degrees outside. We decided we were not going to spend it out on the snowshoe trails and going to the aquatic center did not sound appealing.  So may as well start sewing.  


The first step was to find some room to work I moved all the furniture in the living room and rolled out the Dacron.

Next I laid out the panels and got a general idea of how this thing will go together.  Yep, it's a triangle.  
A really big triangle.

Basting tape is the greatest stuff.  This is basically two sided tape used to hold the seams together with out pinning.

Matching up the seams is super easy with the tape you just line it up and pull out the top layer of tape backing.  Sailrite draws nice lines on each panel that make matching up the overlaps easy as can be. 

Once the seam is matched up I roll up the sail and place a clamp on the cloth so it will fit under the machines arm.  Then line it up with the machine.

Time to zip away.  See? That was an easy little short run.


First run done.  Each seam is sewn twice with a zig-zag stitch.  So time to flip the sail over and sew the other side.  It is probably a good thing it is sewn twice as I'm not a professional at this. But I figure this is about half the price of having a loft sew one up. 

Time to baste and match up seam 2.

Here is what it looks like when you break a needle.   This I think is around seam 3 so things are getting bigger and I was getting a bit of pressure placed on the needle from the weight of the rolled up portion of the sail.   Sailrite suggests planning your sail ahead and building in parts to alleviate some of these problems.  Ultimately I will build three large sections and assemble them.


Two side rolls now it's getting real.

Here is a nice clean run.


Many runs later, you can see the shape of the sail coming together.

A nice top down view of the sewing operation.


Here you can see all three large sections of sail ready to go together.  The head is rolled up at the top of the room, Then you have the body of the sail and the foot at the bottom of the picture.



These longer runs required the use of two rooms.  Time to move the dinning room table. 

All three big sections sewn together take up all of the living room and go up the wall about half way. This took me about 7 hours I figure and I broke 3 needles in the machine.  Like I said, I'm not a professional and I was not in any big hurry.  The seven hours includes stopping for dinner and mixing up margaritas, so no hurry at all.  The corner patches edging finishes and detail work to come in a later posts.














Saturday, January 16, 2016

More uses for those sail scraps

A Dacron Tooth Fairy Pillow for the kids first loose tooth.  This way the tooth fairy can easily find the tooth in the dark.

Tuesday, January 12, 2016

Snow Finally and a Little Disco Dune Sledding




Today we got our first real snow of the winter.  We have had a few splatters here and there but today we got slammed; schools closed businesses closing early.

I got down to the marina and took a few pictures this afternoon once the roads were starting to clear up.  Truth told it was still pretty ugly out there.  The express way must be closed because a ton of truck traffic was coming through town.  Regardless the effort was worth it. Kraken is holding up well under her cover and the supports under the tarp are holding up well.   I peeked my phone in for a few quick photos.  Nice and dry!

We also got out and hit the dunes for a little sledding.  Myles helped me edit a video so we added it in here at the bottom just for some fun.  Wow is it windy down by the lake.

Small Light House at the Marina


Frosty Boat Yard
Frosty blanket

Cold but Dry Inside