Making a Gaff Sail

[Paul H (admin)]

I wonder if anyone has made a gaff sail?

Having used Wifey's sewing machine to sewn up a Mirror sail into a lug sail for Illusion I reckon its not too difficult. There is a great free program called SailCut for designing a sail of any shape or size - it also develops the flat panels that you must cut out before stitching them together.

Chris Waite has found a old gaff for me. I'll start with this on MilliBee, see how I get on and maybe make a larger version.



I've never been totally happy with the Enterprise rig on MilliBee. It jams in the track easily (even with slides) and overpowers in gusts - I'm sure a gaff (or lug) will be better for me.


-Paul

[momist]

I made the Standing Lug sail for Robin 25 years ago, using my wife's, then, almost new sewing machine.  From memory (!!!) I glued the seams using Evo-Stick as well as sewing them with the zig-zag stitch, set up on the machine after some testing.  The machine was given a thorough service (by me) after the sail was complete.  After some research on sewing sails, I purchased some special ball-point heavy grade needles to suit the machine.  These make a slightly larger hole, and do not cut the threads in the fabric which a normal sharp needle might.

The sail has lasted well.  There is one repair where the sail had been chafed through in careless storage, and needed a patch to ensure the hole would not get larger.  And I have had to replace the brass eyelets once due to corrosion.  The really heavy reinforced bits were hand stitched, and none of the stitching has ever given me any concern.  Use a suitable heavy polyester sail thread though.

The design of the sail formed part of the boat plans I bought from the designer, and I bought "proper" polyester tan sail cloth from a chandler in a fishing port - no doubt long since out of business.  I considered using "broad seam" shaping, but it seemed a bit OTT for such a small sail, and I was not confident enough to change what the plans said to do.

[Paul H (admin)]

Ian,

As my original post said I have cut a Mirror main into a lug and seamed the top. I used double sided tape to hold the seam in place.

Previously my wife has run the sewing machine when we added reefing eyes to an Enterprise sail, but I took the plunge and had a go. It was remarkably easy but skill is needed to get an even stitch. I'll post more on Illusion's blog soon.

I'm confident to take on a larger sail now but I don't think I'll join the local sewing circle, unless they have chocolate digestives at coffee time of course.

cheers
Paul