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Make Your Own Sail Pack PDF Instructions #200303 Sailrite Sail Pack Step 1: Overview Taking Measurements

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Make Your Own Sail Pack PDF Instructions #200303 Sailrite Sail Pack Step 1: Overview Taking Measurements Make Your Own Sail Pack PDF Instructions #200303 Sailrite Sail Pack Step 1: Overview taking MeaSureMentS A sail pack mainsail cover (also known as a Stack Pack®, Each kit features sleeves along the top edge of the cover The key to making a successful sail pack mainsail cover is Lazy pack, or Mack Pack®) is a popular adaptation of a for battens or schedule 40 PVC 3/4" pipe (not included in careful measurements. The cover must be large enough standard mainsail cover that is used in conjunction with this kit) to help keep the cover open as the sail is lowered to provide for the sail even if the drop is not “just right,” lazy jacks to make dousing and covering a mainsail quick and to reduce flutter when the sail is hoisted and the but it should also be as small as possible to keep from and easy. Simply drop the sail and zip the cover panels cover is flat against the sail. This design also features a getting in the way while sailing. shut. The two halves of the cover attach below the foot long zipper along the top length of the cover for quick with webbing straps and common sense fasteners. closure and a removable forward mast boot for closing To begin, drop the sail and furl it on top of the boom. Use off the front of the cover. short lengths of webbing or line to hold it in place on The cover is integrated with a lazy jack system (not the top of the boom. Do not pack the sail in place, rather included in this kit) to support the top of the sail pack The system works best with mainsails that have slugs stack it as it would drop when enclosed by the cover. and guide the sail neatly into place inside the cover. The or slides on the luff as they encourage a neat flaking of lazy jack lines are strung from a point two thirds up the the sail when lowered, but it will also work with sails First, measure the circumference of the sail “stack” at the mast to webbing loops installed along the top of the sail that have boltropes run up a slot in the mast. Full length gooseneck (the leading edge of the stack at the mast) pack. These lines can either be tied off at the loops or battens also encourage proper flaking, but the system from the foot of the sail where the cover will attach to run through the loops and alongside the cover to boom will work with sails that have short battens. the center of the sail stack at the top and back around attachment points. (Figure 1). This should be the highest point of the sail stack. Second, establish the “slope” of the stack by measuring the circumference of the stack one to two feet forward of the clew, again from the foot of the sail where the cover will attach to the center of the sail stack at the top and back around (Figure 2). A straight line from the first point to this point should cover the entire bulk of the sail. Finally, measure the length of the sail on the boom from just aft the mast to the aft end of the sail on the boom. Finished Sailrite Sail Pack Kit Sailrite Sail Pack | Overview | SteP: 1 taking MeaSureMentS 2 Step 2: Creating the COver PanelS Using these measurements, pattern the cover right on the Turn the resulting wedge of cloth end-for-end to use as Keeping the IN side facing up, fold both panels to this line fabric. We like to use a soapstone to put easily removable a pattern for the second side. It should fit nicely onto the for a 6-1/2 inch wide fold of cloth. Because the fold is on marks on the cloth. A pencil will also work but may be remaining cloth segment (stagger as necessary) with little an angle, the edges of the fabric at the forward and aft hard to see on darker fabrics. waste (Figure 4). Label the underside of this panel “POUT” ends will not line up. Trim the excess at the forward edge to indicate port outside. so the edges are straight. At the aft end, trim away about First, divide the two circumference measurements in half. 2 inches (or however much is necessary) so the edges are Add 11 inches to each measurement to allow for batten both flush (Figure 6). pockets and hems. Unroll the cover fabric to a length equal to the foot of the sail plus 6 inches (A, Figure 3). Using the two modified circumference measurements (B, Figure 3), put down the pattern as shown in Figure 3. Label the panel surface “SOUT” to indicate starboard outside. (We designate the inside and outside surfaces for construction purposes only. Sunbrella canvas has no IN or OUT side.) Cut out this starboard cover blank from the roll of cloth. Scissors can be used since all edges will eventually be folded under or hemmed to prevent raveling. Trim Next, mark a line on the IN side 13 inches from the top line of the sail pack patterns. Simply measure Trim perpendicular to the top lines down at the forward and B B aft ends (Figure 5) and connect those points with a line 2" Sout on the fabric. 90º 90º A 13" A Length of sail foot plus 6 inches Inside (Pout) B Circumference of flaked sail (at indicated point) divided by 2 plus 11 inches 13" Inside (Sout) Sailrite Sail Pack | SteP: 2 Creating the COver PanelS 3 Step 3: Step 4: Step 5: Pocket PatCheS hems: FOre & Aft Batten PocketS Reinforce the aft edge of the fold (batten pockets) with Create a 3/4 inch wide hem along the forward and aft Refold the top edge of each panel down to the 13 inch a 5"W x 6"L piece of Dacron sailcloth to protect the edge of each panel. Fold the fabric over onto the IN side. line put down earlier on the IN side. The first two inches canvas from wearing through where the battens poke. Use basting tape to hold the fold in place until it can be of the fold will be sewn to form a pocket for 3/4" diameter The weight of sailcloth is not important, 4 oz. Dacron is sewn. Cut an “easing” slit about 3/4 inch deep at the base PVC pipe “battens” (Figure 10). The remaining 4-1/2 relatively inexpensive and perfectly suitable. of the “V” so the hem can be folded flat over its entire inches of single thickness fabric below these pockets length. Sew a single row of straight stitches just along the will be used to attach the zipper that will close the cover inner edge of the folded hem (Figure 9, notice easing slit halves at the top. and abrasion patch). Stitches 1/8" 2" Close pocket 13 inch line Aft end Start by placing a row of straight stitches within 1/8 Open the folded cloth up on each panel and center the inch of the folded edge all along the top side of each Dacron patches over the “V” at the aft end on each panel panel (Figure 11). These stitches will hold the fold in on the IN side (Figure 7 & 8). Use basting tape to hold the place. Next, sew a second row of stitches 2 inches below patch in place and sew all but the aft edge with a row of the fold to create a reinforced pocket that will hold the straight stitches within an 1/8 inch of the patch edge. Cut battens (Figure 12). Put down guidance lines on the away any excess Dacron from the edge to match the “V” fabric to help keep the stitches straight. Put several rows shape of the panels. of straight stitches over the top of the hem stitches at the aft end of the pocket to close it. 6" long 90º Sailrite Sail Pack | SteP: 3 Pocket PatCheS | SteP: 4 hems: FOre & Aft | SteP: 5 Batten PocketS 4 Step 6: Upper heM and Zipper Closure Line Line Turn next to the zipper closure along the top of the If the zipper is too long, it can be shortened with scissors Zipper placed along Zipper placed along Fold Under Fold Under and finished with stainless steel top stops that keep the cover. Depending upon availability, there are two zipper edge of 1" fold edge of 1" fold alternatives: a finished single pull #10 zipper (completely slider from coming off as the zipper is closed. Simply Line separates like the zipper on a jacket with a pullInside tab on Inside Inside Inside Inside press a top stopInside in place over the final zipper tooth on Zipper placed along one side) as long or longer than the top edge ofFold the Under each tape (Figure 18). edge of 1" fold panels or a continuous #10 zipper (no starting block If using a finished zipper, proceed to Bottom Hems. or stopper onInside its ends) with a single pull slider that isInside Inside at least 6 to 12 inches longer than the top edge of the If using a continuous zipper, work the slider onto both panels. Long finished zippers are not always available, A nished zipper wouldA nished zipper would A continuous zipper wouldA continuous zippertapes wouldfrom the aft end with the pull against the fold of but continuous zippers come on large reels that allow for stop at the aft end stop at the aft end run past this aft end byrun past thisthe aft endhem.
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