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 18: Glueing and sewing of the fortification of the nose

1. Cut off the excessive parts of the leading edges with a soldering iron.

Watch Out: Don't cut into the nose bag.

2. Cut the fortification out of an old sports bag or car safety belt.

3. Mark the axis of the fortification over the whole length and also the centre. Mark the centre of the nose bag.

4. Glue the fortification on the sail and apply enough pressure. Check if the marks are aligned.

5. We use paper tape as a reference for the sewing. The first piece of tape is aligned with the sewing of the nose bag. The second piece marks the sewing of the leading edges.

6. The sewing is in 4 steps, always with a straight seam. To stay clear about this, we marked steps 3 and 4 on the other side of the nose. It's meant to be sewed 4 steps at one side at a time :-)

1. Start at the last three steps zigzag seam on the leading edge and sew up to the piece of tape you put over the nose bag.

2. Turn the sail and sew to just over the edge of the fortification following the paper tape.

3. Turn the sail 180° and sew again the last piece you just did. Remove the paper tape that aligns with the leading edge and continue your sewing right at the top of the fortification.

4. Turn the sail and sew the fortification at 1 mm from the border of the leading edge.

It is best to return 3 steps of the sewing at the end of the seam, that will make the sewing stronger.

7. Repeat the above for the other side of the nose.

8. Cut the excessive parts of the fortification with a soldering iron, without cutting into the leading edges!