The Sail

step 1: Putting the plan and the moulds together

step 2: Cutting the sail, Mylar, Dacron and the fortification for the nose

step 3: Putting together and glueing the sail parts

step 4: Sewing the two halves of the sail

step 5: Glueing the two halves (at the spine)

step 6: Glueing the fortification for the stand-offs

step 7: Glueing Mylar or Ripstop as fortification

step 8: Sewing the fortification for the spine and stand-offs

step 9: Glueing and sewing of the fortification for the upper spreader

step 10: Glueing and sewing the Ripstop for the “trailing edges"

step 11: Glueing of the nose bag

step 12: Sewing of the spine tunnel

step 13: Glueing and sewing of the fortification for the central-T

step 14: Glueing of the leading edges

step 15: Marking the leading edges and the nosebag

step 16: Sewing of the leading edges and the nosebag

step 17: Inserting the leechline

step 18: Glueing and sewing of the fortification of the nose

step 19: Cutting out the space for the yoyo stoppers

step 20: The holes for tensioning the leading edges and placing the stand-offs

Step 10: Glueing and sewing the Rip stop for the trailing edges

1. Fold the Rip stop in the middle over the full length in two. The easiest method is to take the Rip stop together between your fingers over a distance of about 10 cm and rub that segment across the hard side of the hardboard, then the next segment of 10 cm and so on.

2. Put the sail with the front side up and the tail close to you.

3. At 4 mm from the back side of the Rip stop, apply some glue over a length of 10 cm.

4. Slide the Rip stop under the sail and press it against the curve of the trailing edge. Make sure that the last part of the Rip stop ribbon comes beyond the sail.

 

Watch Out: this job has be done very strict: the Rip stop must be following the curves of the trailing edge perfectly.

5. Repeat this over lengths of 10 cm until you reach the tip.

6. Glue the front side of the Rip stop against the sail, applying pressure with your fingers. Again, do this in segments. Pay attention that you don't glue all the way, just on the outside of the Rip stop (the bottom part needs to stay open for the leech line)

7. Sew the Rip stop with a "three steps zigzag seam". We start sewing at de tip.

Watch Out: stay away as far as possible from the bottom side, that's where the leech line is running through, so don't sew it there.

8. At the tail we sew the Rip stop from the second Trailing edge with a smooth passing and stay away from the bottom side!