Zeroice Posted October 23, 2003 Posted October 23, 2003 I was looking at duckworks supply page and they have sail material for like $7/ft. It doesn't look two tuff to make sails according to the one for my sunfish and using the poly tarp sail as a patern. From what I see, I could have a set made for under $130. Has anyone tried to make there own dacron sails here? Quote
Steve Downs Posted October 23, 2003 Posted October 23, 2003 I've never made sails but I have made flags out of nylon with the different colors sewn together. I would imagine that it would be very similar. I'll find out for sure when I get to that point. Quote
High C Posted October 23, 2003 Posted October 23, 2003 I just made a sail cover, with my wife operating the sewing machine, from a kit frim Sailrite.com. It's made od Sunbrella, which is heavier than Dacron sailcloth. It took a special heavy needle, but was not too difficult. The hardest part is handling the large pieces of cloth. Quote
Barry Pyeatt Posted October 23, 2003 Posted October 23, 2003 My nephew made a new dacron sail for the old sailing surfboard that I built years ago. It is the same as a Sunfish sail. He said it went together easily and wasn't a problem to sew, (for his wife). He also had her sew a window into it made from heavy mylar drafting film. Previously the sails had been made from a variety of materials. Cotton, polyethelene sheeting/duct tape, poly tarp/duct tape, Tyvek/duct tape and painters canvas/sewn. He said that he had used the new sail several times this summer and it worked well. He followed the same instructions as the Polysail kit. Quote
Jan Williamson Posted October 24, 2003 Posted October 24, 2003 I used to do upholstery professionally, and the one thing that will really make a difference with handling the large amount of fabric, to make a "U" shaped infeed and outfeed table around your machine. Maybe out of sawhorses for the bases or something but level with the machine table. the left side of the sewing machine needs the table. At least two feet wide. See drawing below [attachment over 4 years old deleted by admin] Quote
Greg Luckett Posted October 25, 2003 Posted October 25, 2003 Jan, Maybe I am just too tired this evening, but I don't get it. Your description does not seem to make sense with the picture, to me that is. Could you elaborate some more. I am very interested in trying my hand at sewing sails and covers and re-upolstering my boats cushions. Thanks, Greg Quote
Jan Williamson Posted October 25, 2003 Posted October 25, 2003 Sorry, I am not like Barry in my writings and drawings. His works leave few questions If you have an industrial type machine it usually has it's own table with machine stting down into it level with the table, but if you don't and have a home type portable, you can still build a table around it, you just have to build it around the "arm of the machine so you have a flat surface The outfeed table allows bunches of fabric or heavy fabric to be supported while you are sewing it. Here's another picture, without going into adobe photoshop anyway [attachment over 4 years old deleted by admin] Quote
Greg Luckett Posted October 25, 2003 Posted October 25, 2003 Jan, This makes sense to me now. Of course I have slept and had a half a pot of coffee now, but your latest picture and explaination make good sense to me. Thankyou! Quote
Tim Diebert Posted October 25, 2003 Posted October 25, 2003 Here is a topic that interests me. I am going to be recutting an older (and much larger) headsail into a genoa for my WE. I am fortunate in that I own a beautiful industrial sewing machine. Making the large outfeed table that Jan has so excellently drawn is an great idea and something I can do. I have three large movable tables I use for infeed and outfeed on my table saw that could do double duty for the sewing rig. Handling all that cloth was one of the things I wondered about. Thanks for the tip. The other thing I am wondering about is our machine does not do a zig zag, but just a straight stitch (although at 400mph). I notice that most sails are sewn with a lot of zig zag. Do you'all think just a straight stitch would be OK? If I can do an ok job on the head sails, I would like to do a main out of proper material. The poly sails work great, but I would like some real ones on there eventually. Good 'thread' ...oh....and...Hi Guys....back to lurk mode. Quote
Jan Williamson Posted October 25, 2003 Posted October 25, 2003 I think the reason for the large zig-zag is so the strength of the fabric is not compromised. When you sew in a straight line with woven fabric, that part of the fabric is weaker, and the more times you sew over it the weaker it becomes. I have a straight stitch too but I will probably make the polysail at first. If I become a sailing fanatic and wear them out, I may consider getting a zig-zag. It would be great if you could have a univeral table that would accept an upholstery walking foot , zig-zag , or what ever you have. I got a catalog from sailrite, and they sell machine heads. You may be able to buy a used reconditioned one for less. I bought my straight stitch from a manufacturer of Hydro-fit. Makers of water fitness equipment. Quote
Tim Diebert Posted October 25, 2003 Posted October 25, 2003 Just asked my wife and she said this one is straight stitch with no options....though, I am going to do a bit more research to confirm. This one is a Pfaff...sucker weights a ton...I hate moving it, or rather my back does. I wore out one poly main, and have a Poly Sail kit for a new one which has much better/heavier poly. I have not made it yet because I was thinking of a real one. Hell, I might just have it made for me if I can scare up the pesos. That said, I don't figure there are too many compromises using the poly. It is just the embarassement factor....and having to explain to folks that ask what kind of sail material that is. I just tell them duct tape and a firewood cover. Quote
Jan Williamson Posted October 25, 2003 Posted October 25, 2003 I believe the sail zig-zag pattern is wider than a standard zig-zag, which is usually not wider that about 3/4". But since I know very little yet about sailmaking, I don't know what the difference would be. The problem with those undustrail machine heads are that you seem to have to lift them with one arm and of course try to line up those little hinges in the table with the other hand, which is a back wrencher. I love having to move my machine table and all, (no wheels). screeeee-rape Quote
barnacle5 Posted October 25, 2003 Posted October 25, 2003 hello all. barnacle 5 here and I sew for a living too ( www.racingleather.com ) there have been many sails sewn together with straight stitches. I have done so myself and they worked fine. set the machine on a fairly long stitch length ( about 5-6 stitches per inch ) and sew it withing 1/8 inch ofthe edge of the material. it wil take two rows at each seam just like the zig zagged seams . another alternative is to look around a flea market and pick up one of the older household machines ( all metal gears) that has the zig zag option ( like a singer, universal, or a white) many of these can be bought for 50.00 or less and put the hand crank on it from sailrite, or build your own . it will sew the seams fine. you can use your commercial machine for the corner patches. I recently pourchased a LZ1 walkingfoot zig zag from sailrite to use in our business and to make some sails on. small machine but it does great work and it is easy to move around. uses the same bobbins and basket case as the home machines I mentioned before. when you put your panels together use the seamstik tape before sewing them. any questions feel free to ask. have a good one. bill Quote
Tim Diebert Posted October 25, 2003 Posted October 25, 2003 All very excellent info Bill, thanks. Appreciated. Your work looks great. I like all the images...vintage bike racing....very nice. Good shot of Booger. Who are the cats doing burnouts on the crotch rockets? Looks maybe Gixer and a Honda? Fun bikes. Got to ride the new BMW K1200 R this summer. Monster bike. So we have a sewing master in our midst folks....and Jan is a X upholsterer ....how fine is that? With all the talent on this list we could rule the world........na. Sorry to kidnap the thread...but thanks for all the info folks. Quote
Charlie Jones Posted October 26, 2003 Posted October 26, 2003 SailRite has an excellent set of (small) books on sail making. Not too expensive and each one covers a different kind of sail. You could get the one covering mainsails for example. They also can supply every bit of hardware, thread, etc that you need. By the way- Sunbrella is far easier to sew then is Dacron. Also- my wife,who did sail repair, sprays silicone on the material to help the needle go through, particularly when using the sticky tape. Quote
Greg Luckett Posted October 26, 2003 Posted October 26, 2003 Charlie, I went to Sailrite's web page. I do not see any books offered. Can you help direct me to them? Perhaps I need to call instead? Thanks. Quote
barnacle5 Posted October 26, 2003 Posted October 26, 2003 they are clients. I think they live in alabama. everyone on the picture pages are wearing one of my suits except for Booger. I really like the one of the two guys with the white and yellow suits. looks like they are riding the same bike. instead of spraying the fabric you can place a piece of oiled felt or foam on the machine above the needle and it will lubricate the thread as it pulls through. most thread problems are tension adjustment or needle size is usually too small. try a larger guage to see if it helps. also a dull needle will generate enough heat to melt or fray the synthetic threads. dacron is slippery and harder to sew. you will have to increase your foot pressure in mopst instances for proper feeding. the other poster was right on on the support table. material falling over the edge of the table will flex the needle and cause missed stitches . flex it enough and it will break on the striker plate . dang may as well show a picture of my homebuilt titmouse ( about 15 years ago) if I can load it. have a good one. Bill [attachment over 4 years old deleted by admin] Quote
barnacle5 Posted October 26, 2003 Posted October 26, 2003 actually I meant that I built the boat 15 years ago. the picture was taken last week at the lake. here's another under sail. [attachment over 4 years old deleted by admin] Quote
Charlie Jones Posted October 26, 2003 Posted October 26, 2003 Greg- I can't even get to the online catalog for Sailrite, but in the 2003-2004 catalog the books are on page 51. They have a set of five (#36101) for $49 and each individual one is sold seperately. The one for the Mainsail is cat #36201 and sells for $11.95 The Jib one is #36301 and is the same price. There is one for Spinnakers, Storm trysails and Stay sails. Probably won't need those for the Weekender huh? They also list a complete home study course in sailmaking for $195 Bill- Nice looking boat. I've always thought old Sam's Titmouse was a pretty neat little boat. Quote
barnacle5 Posted October 26, 2003 Posted October 26, 2003 yes, I like his designs and his philosophy on boatbuilding. I built this boat over a winter while I was recuperating from a motorcycle accident ( someone rearended me at 75 mph) . it is a little overbuilt and I put a steel plate centerboard inplace of the wooden lead weighted one. I built the oak frames from lumber from my own trees ( used to have a sawmill) and the rest of the boat was built from leftovers and dumpster scraps ( old motorcycle crates use to be a cheaper grade mahogany) . the first sails I built for this boat were straight stitched and worked fine . I passed them on to another sailor after I built another set. I think he is still using them. I'll tell scraps you like her lines. have a good one. bill Quote
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