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Better Sailing

How to Repair Sails On Your Sailboat

Even if you try to avoid any sail damage to your sailboat, there will be a time, unfortunately, when they get damaged at sea. So, what happens in the event of sail damage? Of course, the fact is that you’ll have to repair them while at sea and then quickly do a damage assessment. For that, you will probably need someone to lend you a hand and a flat surface to place the sail open. But before we get to the details on how to DIY repair a sail tear on your sailboat remember to be prepared for any unexpected scenario. In other words, having the right tools and supplies onboard gives you a huge advantage in dealing with the problem. Some of the basic tools include a waxed twine, a selection of sail needles, sharp scissors, spare webbing, and a sticky-back Dacron. Let’s move on and see the details!

Stitching your Sails

It is of great importance for a sailor to be able to stitch a sail by hand. If you know how to do this, it’s really practical in case of a chafe or of any other torn seams. The process is really simple. Firstly, make one pass to stitch on one set of diagonals as well as to the opposite direction and then fill in the other set. This can be applied in case you are following an existing zigzag stitch. Moreover, the sailor’s palm will facilitate you in order to force the needle through the fabric, and pliers will help you pull the needle through it. Remember to melt the ends of each knot with a lighter to prevent any loosening, as well as try to make tight stitches to ensure a strong repair. Buy a Sail Repair Kit From Amazon

Patch Repairs

For repairs that are not on a seam, a patch fix is necessary. You can use a Dacron patch for almost everything except spinnakers. Dacron can even stick to many laminate sails on the film side, but not on some resin-based and silicone-covered sails. In addition, dacron tapes come in different forms of thickness rolls and you can also buy larger sheets. Naturally, sails are not flat and they’re made up of panels that create depth. However, due to its design, when the surface you lay it on is flat it might pose you a problem. So do some temporary tucks and folds in the cloth, but away from the rip, and try to keep it flat. So, be patient and follow the below-mentioned procedure:

• The space you’re going to “work” is essential. Find a dry and safe place with a flat surface like below the saloon table or even on a chopping board.
• Always clean your fabric of salt with a freshwater rinse. Then allow a few moments for the fabric to dry. Continue by removing any residues with rubbing alcohol. This tip facilitates the drying process, as the alcohol evaporates.
• Most of the time, some sails (mostly white), tear in lines. For that reason, they shouldn’t be pulled too close together or overlap each other. Otherwise, their shape will change, and thus loading will be created. In case the tear has gone off in different directions repair the longest first.

>>Also Read: Best Sail Repair Tape

Seam Repairs

In order to make sure that no seams are starting to appear, try to check your sails daily. It’s not particularly hard for a seam to be unstitched, right in the middle of your voyage. So, if you see any loose stitching, put the sail down immediately, if possible, in order to get it fixed. Stitching a seam back together is a task that requires some time and attention. However, it’s much easier than dealing with ripped fabric. When you stitch seam you just work your way methodically back through all the holes. Try finding a comfy place on deck to work because it might be difficult to move a large sail down below. And remember that “a stitch in time saves nine”!

Patch and Glue

Sail damage can be also caused by a tear to the sun protection on roller-furling headsails. If that happens don’t put new holes in your sail in order to stitch up the tear. This will be really time consuming. Use instead some sticky-back which definitely is an efficient and fast solution. Although you have to take the sail down and put it back up to do that, sticky-back is the answer to this problem.

The first step is to cut the corners of the patch round in order to keep them from peeling off the sail. Then clean the whole area from the repair with acetone, and once the patch is ready, rub from the center to the edge with a scissor handle in order to make sure that it’s totally adhered. Furthermore, sticky-back patches work efficiently for small holes in the actual fabric of the sail. If any holes appear in the fabric then use patches on both sides of the sail, an inch or two larger than the rip in all directions. Keep in mind to slightly counterbalance the two patches so that the load won’t spread out around the repair. Also, take with you ripstop sticky-back to match the colors on any downwind sails, as well as small, pre-cut round patches, which can be practical for small holes in nylon sails.

A lot of spinnakers are no longer stitched and are put together just with tape, so if you need to make a repair it’s a particularly easy task. For most repairs a sticky back spinnaker repair tape is fine. Try not to change the panel’s shape and don’t use too much cloth for the patch. This way you’ll avoid generating unnecessary loads and stress lines. Instead, use the same amount of cloth for the patch so it moves and stretches simultaneously. Also, in case that a tear passes through the panels, repair one panel at a time and not all together. This way each panel is going to move and stretch as it was designed to.

One of the things that need occasional repairs on your sails is fabric. Fabric is one of the most vulnerable parts of your sails. Most of the time, when a sailboat uses its slab reefing it will subsequently wear out the webbing attachments to the tack rings. Therefore a failure of the webbing connection to the mainsail luff slides will be caused. As I’ve mentioned before, the most practical and easy solution to this is to be equipped with twine, a webbing, a needle, and a sailor’s palm . In case you don’t have the correct size of webbing, then Spectra cord can attach a slide fairly well.

These repairs are permanent and won’t take you more than an hour. Another sail damage for many sailboats with full-length battens might be caused by the connection point between the batten and the luff track on the mast. The best thing to do if that happens is to apply West System epoxy along with 3M adhesive sealant 5200 fast cure . This will untie your hands and is also an easy task to perform.

Common Damage Areas

• Spinnakers : Anything sharp can damage the spinnakers. Especially near the boom, so check that everything is taped up. Also, spinnakers tend to get caught between the shrouds and above the spreaders so consider closing off this gap with a bungee.
• Spreader and Rig Chafe : When you’re sailing downwind the mainsail spends a lot of time relaxing on the rig. Keep in mind to fill your spreaders with pipe insulation. Moreover, consider having extra reinforcement patches for the spreaders on the batten pockets and at each reef point.
• Spreader Ends : Always reinforce the sail and put smooth cages around protrusions. In addition, wrap foam around your spreader caps on long voyages.
• Bottom of the Headsail : Try to lower the halyard enough in order to reach the damaged section. Then reinforce with a sail repair tape . In case the conditions don’t favor you to do so, keep a wrap in the sail to take the pressure off the damage.

Summary – How to Repair the Sails

All this is much easier if your sails aren’t damaged in the first place. But, I know for a fact that sometimes you can’t prevent it from happening. In any case, always be alert to what is going on with the rags. Moreover, always carry a sail repair kit (link to Amazon) on board especially for long-distance cruising. Before leaving for any long trip have also a sailmaker service to check your sails for any weak points. Last but not least, in case that your sails are damaged at sea reinforce any loose stitching immediately and tape both sides of repairs to ensure extra strength.

Peter is the editor of Better Sailing. He has sailed for countless hours and has maintained his own boats and sailboats for years. After years of trial and error, he decided to start this website to share the knowledge.

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It’s Time to Set Sail!

Breese Sailmakers specializes in building, repairing, and maintaining sails for your dinghies, one-designs, classic wooden yachts, good old boats, and the modern cruiser.

We’re a small loft, which means we’ll work together to make sure your sails are designed and built for your type of sailing. We’ll help with sail-handling systems, splicing, lifelines and running rigging. Year after year, we’ll keep your sails and canvas in tip-top shape with our annual inspections, repair, cleaning and storage service.

We’re proud and humbled that our reputation for excellent service and support extends well beyond Rock Hall and the Chesapeake Bay. The sail loft has repeatedly been voted “Best of the Bay” by the readers of the Chesapeake Bay Magazine.

Rock Hall Weather

A Sailmaker's Guide to Patching

Mother Nature can wreak havoc on even the best sailing gear and equipment. Thankfully, with repair magicians like Quantum’s Eric Grigsby here, you don’t need to fret if a nasty storm or big breeze damages your sails. Eric explains what goes into common patching repairs and how he makes sails as good as new.

A lot of the repairs you’ll read about here can be avoided with regular inspections (Catch the wear before it needs a major fix!), but, at some point in your sail’s life, it will likely need repair for any number of reasons ranging from a nasty puff to crew error. Some of the most common issues I see, such as torn or chafed areas, can be repaired with patches. The following descriptions will give you a look at the different types of patches used to repair specific damage to both cruising and racing sails and make them like new again.

WINDOW PATCHES

A window patch involves completely removing the torn or damaged area and replacing it with new cloth of the same type. Window patches is the more common approach with Dacron cloth and nylon spinnaker cloth than with laminate cloth and are usually done when there is significant damage. The torn cloth is reassembled using masking or insignia tape, and then the damaged area is pinned out flat and sectioned off with double-sided adhesive tape. The new cloth is then positioned with the fibers in the correct orientation, and the old cloth cut out on the opposite side of the sail and the seams stitched. If the window patch is executed as I’ve explained, it will not affect sail shape or strength. However, it is essential to first remove the shape in the sail, pin the area flat, and orient the warp and weft fibers in the correct direction in relation to the area you will be replacing on the sail. Warp fibers run with the length of the roll; weft fibers are woven perpendicular to the warp yarns. Many cloths also have bias and scrim yarns in them. It is critical to match up the fibers because they act as load paths that take the strain and shock-loading the sail is subjected to while underway. The new cloth should be as close as possible to the same weight, style, and yarn type if a clean repair is to be made.

LIKE A PUZZLE

A tall-ship sail's tear is taped back into place in preparation for a window patch. The damaged material will eventually be removed when the new panels are stitched in.

NEW MATERIAL

The new panels are pinned down over the reassembled damage. Next, it will be stitched in place and the damaged portion removed.

BAND-AID PATCHES

A band-aid patch uses a piece of cloth with adhesive backing and applies it to the damaged area on both sides of the sail and then is usually stitched down. This repair is common for small holes and tears and is often the preferred method for repairing laminate sails. A small tear or pinhole in a spinnaker can be repaired using an insignia patch applied to both sides. An insignia patch is a lightweight polyester woven cloth with a pressure-sensitive adhesive (PSA) backing, which makes it excellent for small spinnaker and laminate repairs. The surface is wiped clean of any dirt or salt before the repair is made. The patch cloth must be applied flat and rubbed down vigorously to activate the pressure-sensitive adhesive.

A simple tear is no match for a band-aid patch appropriately applied. Here the patch is already applied to one side and is being prepped for the next step.

Straight forward fix

The patch is applied to the other side and once cured the sail is good to go.

Laminate sails can vary greatly, and their yarn layout and construction is typically a bit more sophisticated and delicate than conventional sail cloths due to their Mylar construction. Some laminates have Mylar films on both sides; others have taffeta films and even Mylar taffeta combinations with everything from carbon to Kevlar yarns. Often the best approach to repairing large tears on laminate racing sails is Ultrabond (hot glue) band-aid patches with minimal to no sewing required. If the yarns are fully severed, then new cloth of the same or similar style and weight will need to be applied in order to make a proper repair. The yarns in laminate cloth create the structure of the sail and act as load paths similar to the individual fibers that comprise more traditional cloth like Dacron. A cover layer of insignia or spectra/Kevlar PSA should be placed over the repair on both sides of the sail. The patches need to be different sized, with one larger than the other to prevent any hinge points, which is a laminate sail’s worst nightmare. The repaired area needs to be left flat to cure before it is ready for use on the water. Smaller tears and damage to the film can be made using Mylar PSA on both sides, although, just like other adhesive tapes, the sail surface must be clean and flat before application.

IT HAPPENS TO THE BEST OF US

Opps...your bowman fell through the tack! No worries, we can fix that, too.

Nothing a little band-aid patch and a few stitches can't fix.

Now back to sailing.

OTHER PATCHES

Corner patch/broadseam tearing.

Sometimes laminate sails can begin to break down along hinge points, such as at the edges of patches, broadseams, and leech belts, where there is a sharp transition from thick to thin cloth. For broadseam tearing, a repair using a triangular type of patch with a laminate structural patch on one side and staggered cover patches on one or both sides with sewing around the perimeter of the inner patch will do nicely.

For repairing tears around corner patches, it is common to extend the panels of the patch. This not only covers and reinforces the compromised area of sail, but it also moves the hinge point farther into the sail where the cloth still has integrity. Corner patches should always be offset on laminate sails to help prevent the kind of damage often found on clew patches.

CHAFE PATCHES

Shroud chafe is a common sight on batten pockets and can usually be repaired with a little insignia or Dacron tape. Spreaders can also cause chafe and puncture holes in sails, so an insignia reinforcement patch should always be used wherever the sail comes in contact with standing rigging or stanchions. Insignia tape is versatile and can be used effectively and with minimal weight gain on nearly every cloth type.

LUFF TAPE PATCHES

Luff tape patches are another common patch, in this case made to a sail’s luff tape. Both racing and cruising sails see luff tape wear at high-load areas such as the head, batten pocket locations, and reefs. On larger racing yachts, a strong reinforcing tape is needed to withstand the heavy chafe they see on their mainsail luff tape. A cloth like Hydranet, cut on the bias and sewn on to high chafe areas, will take a lot of abuse and save your luff tape from being chewed up beyond repair. Spectra and Kevlar cloths are also good to use for this purpose as long as they are cut on the bias to ensure that both fibers will be working. On cruising headsails, the section of luff tape at the head often needs to be repaired due to UV exposure which breaks down the fibers in cloth over time. The tolerances are so tight on many furling forestays that lighter cloth like insignia needs to be used for this repair to ensure the boltrope will still fit.

A COMMON WEAR POINT

A nicely placed Kevlar patch makes this luff good as new.

LEECH BREAKDOWN

The leech of an upwind sail can break down over time, particularly with laminate racing sails. A great way to strengthen the edge of the leech on lightweight laminate sails is to apply a larger insignia belt cut into a wave formation rather than a straight cut. This eliminates any future hinge point. Often a recut and wave insignia is all your leech needs to get it flying correctly again.  

IT LOOKS A LOT WORSE THAN IT IS

Even gnarly damage like this can be repaired.

A few layers of material strategically ultrabonded over the damage and the sail is ready for use again.

With the right tools and know-how, almost any repair can be made to a sail as long as the cloth still has sufficient integrity. Some smaller repairs can be made onboard , while larger repairs will require the use of a loft and qualified sailmaker to breathe life back into your sail. For offshore cruisers, I highly recommend having a well-equipped repair kit to make emergency repairs. Check out our offshore repair kit checklist or call your local Quantum loft and they can help you assemble the right kit for your needs.

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The DIY Sail Repair Kit

If you’re going to sail you’ll be doing some stitching. No two ways about it. Don’t jump into the $100 do-everything kit. Start with a modest kit, adding tools and materials only as your skills grow and projects require them. You already have most of what you need in your other supply lockers or tool boxes. Study a good book on sail and canvas repair, concoct a few small projects for practice.

Work Surface – A wooden cutting board is perfect for small projects, much better than plastic.

Sailmakers palm – Get one that fits. Left-handed palms are available. A Dremel can smooth out the sharp edges, so your palm is as soft as a true sailmakers palm.

Needles – Get an assortment, size 12-18. Smaller numbers are larger needles. A number 16 is a good match for #4 whipping twine, your workhorse thread.

Waxed whipping twine – You can wax as you go, but pre-waxed is handier. Robline #4 is our favorite. It is heavier than machine thread, so it will last longer. And its strong enough that if you double it, you don’t need to back-fill in each zig-zag stitch. Heavier twines are used for webbing and around eyes, but for field repairs you can just use more strands of #4. Get a few spools; white is good for sails, dark colors are handy for marking lines.

Safety Pins and Straight Pins – You’ll want these for holding fabric. Double-stick seam tape helps, but if youre working in the wind or in tight spaces, pins seem to work better.

Awl or icepick – Essential forcing holes through material to stiff for palm or even stitching awl alone.

Stitching awl – These tools are handy when you can’t reach to both sides, but most jobs are more easily fixed with a needle and palm.

Pliers – Sometimes the needle requires a little encouragement. The one in your toolbox is fine.

Lighter or Soldering Iron for Sealing Edges – If you can’t turn a seam under soldering the edges prevents fraying.

Cutting Tools – Although a knife, razor, and seam ripper all have their place, start with scissors.

Materials – Some scraps of sailcloth and canvas are useful, but webbing, soft leather or elk hide, Sunbrella, and sail repair tape are just as essential.

Fids – Handy for loosening knots and splicing, get a standard fid before you start coveting all of the fine implements for splicing double braid. (A Fistful of Fids, PS July 2006).

Wool Yarn – Tell tales are perhaps the most common item, and though other materials fly more easily, wool seems to dry fastest and not get stuck to the sail. Some attach them with sail tape. You can also thread them through the tiniest possible hole with a knot on each side. Instead of struggling to thread fat yarn through a small needle (hint, push the needle onto the thread), thread a double strand of light thread through the needle, lasso the thick thread and bring it back through.

Household needles and thread – Include an assortment of smaller needles and thread for repairs to upholstery and clothing. White and several colors in heavier weights.

Fasteners – Once you head offshore its good to have a few grommets and a grommet kit, as well as some spare fasteners. ,

Now practice – If you can find nothing that needs fixing, splice and stitch a loop at each end of a short piece of old double braid-about a foot will do-youll find plenty of uses for it.

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Come on guys, anyone who has used a stitching awl knows that you must have access to both sides. Your quote: “Stitching awl – These tools are handy when you can’t reach to both sides, but most jobs are more easily fixed with a needle and palm.” shows your lack of experience.

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Taking care of your boat from the deck up

Taking Care of your boat from the deck Up

Welcome to Sailors Nautical Services, where expertise and quality craftsmanship meet! Owner and operator Walt brings an impressive 30 years of sail making and canvas experience to the table. With his unmatched knowledge, you can trust us to provide repairs that not only maintain the shape of your sails but also extend their useful lifespan. Our team’s clever modifications will make your canvas more user-friendly and efficient, ensuring a seamless sailing experience.

But that’s not all! We go beyond sail and canvas services. Our comprehensive splicing and rigging services are second to none. Located just minutes away from major marinas and the Intra-Coastal Waterway, our well-equipped loft is strategically situated for your convenience.

And, we understand the value of your time, which is why we offer convenient pick-up and delivery services. Don’t hesitate to reach out to us now to request a free quote. Sailors Nautical Services, fixing your boat from the deck up!

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We can repair almost anything! From minor repairs to extensive damages, regardless of the brand, Hallett Canvas & Sails will provide repair services that will not only complete the specific repair but will also carefully examine the entire sail or canvas item to ensure quality product before completion. As long as the material in the sail or canvas product is not rotten or unserviceable, we can repair it. For prompt service at reasonable rates, bring your sail in on a Monday with repairs done by the following Friday, just in time for the weekend, even in the busy season!

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At our 5000sq. ft. loft, we carefully wash, check, repair, evaluate and store your sails and canvas. In 2011 we added our specially designed wash tank which circulates the cleaning products among the sails and canvas to get a thorough cleaning. After the Canvas and sails soak, they are pulled or removed from the tank, lightly scrubbed, and rinsed. They are then dried, carefully wrapped and stored until your boat is ready for them. Our service has no hidden costs. For the low price we wash your sails or canvas, evaluate the sail or canvas condition, give you an hour of repair labor, and provide storage for the winter.

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Often a sails shape is blown out and baggy, nevertheless the integrity of the cloth is still good. This is common among older Dacron sails. Dacron is great because it will last a long time but it will also eventually stretch over time. We can re-cut the shape of the sail to increase its performance and your ability to trim it properly. We can also re-cut sails that have never trimmed correctly, that were purchased from other lofts. Re-cutting is not just confined to sails. We also alter and correctly fit canvas that is baggy, or too tight.

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We can give you a professional evaluation of your sails or canvas. This is standard with winter service to let you know how well your sails or canvas are holding together. This is a FREE service that we provide. We also do evaluations for insurance and brokerage deals.

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About Hayes Sails

Combine old fashion sailmaking & canvas methods with today’s modern technology..

Hayes Custom Sails was formed by Rod Hayes in 1973 and our 3000 plus square foot loft was constructed that same year. Philip Doggett took over the loft in 2016 and along with Rod’s part-time assistance. We continue to be one of the last independent sailmakers in South Eastern Chesapeake Bay Region. Throughout the years we have custom made thousands of sails and repairs, from repairing the Schooner America’s main sail to small day sailors. In 2018 we partnered with ElvstrØm sails to become a Sale Point for Virginia and the North Eastern Carolina region. This has allowed us to combine old fashion sailmaking & canvas methods with today’s modern technology providing our clients with good performing sails and custom fitting canvas work.

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Since opening in 1976, personal service has been our specialty. We take the time to know you and your sailing needs so we can recommend the best options for you whether its time for new sails or repairs and alterations.

We are well known for our fast, high-quality sail repairs, and comprehensive winter service programs.

For the last 35 years we have built customized new sails using state-of-the-art, computer-aided design and plotting equipment, and are still the only CAD-CAM loft on Cape Cod. In fact, there are very few independent saillofts left in the United States, and we are proud to be one of them!

US Mail: P.O. Box 517, Cataumet, MA 02534

Why 138 size thread? Yes, some "canvas/sail lofts" will say 92 thread has nearly the same strength as 138. However, as sailors, we are also concerned with chafe and longevity . With exception of light duty sails, most sails are manufactured with 138, the industry standard.

Owner Kurt Martin was fortunate to have honed his skills in two of the countries premiere sailing/racing locations. He was born and raised in Milford Connecticut, the headquarters of North Sails. Working at North Sails, Kurt gained diverse experience in various aspects of the sail industry from Grand Prix America's cup sails to one-design. He later moved to the renowned sailing capital, Annapolis Maryland. There, Kurt gained further experience as Service Manager with Sobstad Sail Loft (now known as Quantum). Kurt holds a Sailing Instructor Certification from US Sailing and is a licensed Captain through the US Coast Guard. When he is not repairing sails, he enjoys being on the water and teaching and sharing his love of sailing and boating with others.

Sail Repair Fort Myers Copyright © 2008 Web Site Design by SpiderSights.com

Boat and Yacht Service and Repair

One of our current restoration projects:  A 1950's era Maine Friendship Sloop.

Full service at reasonable rates by a Master Boat Builder / Rigger, and accredited Marine Surveyor.

Serving Erie, Pennsylvania and

the Lake Erie Region

Specializing in:

Fiberglass and Gel Coat Repair and Restoration / Sailboat Rigging / Custom Woodwork / Brightwork Restoration / Traditional Boat Construction / Small Boat Repair / Seasonal Maintenance / Marine Electronics / Marine Electrical and Plumbing / Solar Power Installations / Epoxy and Composite Technology / Marine Diesel Service / Boat and Yacht Surveys / Insurance Claims 

Our Home Port:  Presque Isle bay in beautiful Erie, Pennsylvania.

Quick Links

Erie Yacht Club Weatherlink

Lake Erie Weather Buoys

A Carl Alberg designed Cape Dory sails again after being totaled in Hurricane Katrina.

Hall Boatworks

Copyright ©  Boatworks . All rights reserved.

Ralph DiMattia Sailmakers, Inc.

• The Loft Sailcloth Bags

Ralph DiMattia Sailmakers, Inc. provides a full complement of sail and rigging services to Boston and the South Shore, combining the tradition of old fashioned quality and service with state-of-the-art design and fabrication.

Please visit our loft or contact us for a quote.

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phone: 617-328-1100 fax: 617-328-1102 email: [email protected]

Monday - Friday 10am - 5pm Saturday 9am - 12pm

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