Custom Sailmaking: Design, Cut, & Assembly (2-Day Workshop)

Have you ever wanted to design and construct your own sail from scratch, while deepening your understanding of optimal sail shape? This intensive, hands-on workshop is for you!

Join our experienced sailmaker, Francois, and a small group of classmates for a two-day deep dive into the craft of custom sailmaking. You will learn the entire process, from initial design concepts to the final finishing details, culminating in the creation of a custom sail.

What You Will Learn

This course provides comprehensive instruction in essential sailmaking techniques:

Day One: Design, Prep, and Broadseaming

• Sailmaking Overview: Understand the process from acquiring dimensions to designing and constructing a sail
• Sewing Machine Basics: Receive hands-on instruction in the safe and effective operation of industrial-grade sewing machines commonly used in sail lofts.
• Sail Design Principles: Learn how to use design specifications to determine sail shape, including understanding camber, draft position, and aspect ratio.
• Material Selection: Guidance on choosing the appropriate fabric (e.g., Dacron, laminate) and weight for different applications and desired performance characteristics.
• Layout and Broadseaming: Learn the critical steps of laying the chosen fabric out on the floor and precisely cutting the individual sail panels. You will then practice broadseaming—the technique of creating a curved seam to build shape into the sail panels.
• Panel Assembly: Techniques for accurately aligning and stitching the shaped panels together to form the complete sail body.

Day Two: Finishing work

• Patches: learn learn how to cut and install patches at the highly stressed area to distribute load effectively
• Tabling: master the technique for installing the tape on the edges for strength and to maximize edge stretch
• Finishes: We will complete the sail with all of the finishes such as window, leech line, rings, and hanks.

Location: This course will be taught on location in East Weymouth, MA.

Note: This workshop requires a minimum of two students to run.

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