A tale of two sails!

it was the most traditional of times and yet the most modern?
Apologies to Charles Dickens for bastardising one of literature’s most iconic opening lines.

But looking through my order list I was struck at the varied nature of the sails we had on order! We are currently building sails for everything from the smallest pram dinghy, trailer sailers, traditional cruising yachts, Sydney 32 and 38’s right up to canting keel Cookson 50’s. Each sail has its own nuances and requirements.
Let’s compare two sails-
A full on racing Laminate designed sheerly for speed but with some concessions for longevity for club/ regatta racing on a Sydney 32.
The other a Dacron Sail being built for “Westwind”,  a beautiful classic yacht, indeed the first yacht ever built by the legendary Jock Muir in Tasmania.

Zeptyr Membrane


Firstly, let’s look at a modern Membrane sail, in this case a sail we are making for a Sydney 32, featuring Zeptyr Sails technology, made in Sydney Australia and finished in loft by your scribe. Featuring corner to corner stringing, we have previously made up a dozen or so sails in an earlier incarnation. And were overwhelmingly happy with so many aspects of them, particularly their longevity (some sails are still going after 10+ years, amazing for a membrane)! It is fantastic to see them back on the water with new features and modernisation.  

Creating a modern laminate sail requires an intricate blend of technology, craftsmanship, and material science. At its core, the process begins with selecting advanced materials, such as carbon fibre or aramid, known for their strength and lightweight properties. These fibres are meticulously arranged in specific orientations to optimize performance, balancing durability with flexibility.

The next step involves precision lamination, where layers of film and fabric are bonded using high-tech adhesives and controlled heat. This ensures a seamless integration, reducing drag while increasing efficiency. Computer-aided design plays a pivotal role in shaping the sail, allowing for exact calculations and tailoring to suit the unique demands of each vessel.

What makes a laminate sail truly modern is not just its construction but its customization. From aerodynamic enhancements to UV protection, every detail is considered. The result? A sail that embodies speed, resilience, and innovation, pushing the boundaries of what’s possible on the water.

The second sail is a Dacron Cream mainsail for “Westwind”, the first boat that the legendary Jock Muir built in Tasmania, I was admiring her at my recent venture down to Hobart for the Wooden Boat Festival. Her current custodian (no one ever owns boats like these) Chris Dicker approached me by referral to build a new mainsail for her.

Westwind on show

Westwind under original mainsail (to be replaced)


While modern laminate sails showcase cutting-edge technology, traditional Dacron sails tell a story of time-honoured craftsmanship and enduring utility. The process of making a Dacron sail begins with selecting the fabric—a polyester material prized for its durability, affordability, and versatility. Unlike laminates, Dacron sails are constructed using woven textiles, which provide a robust yet forgiving surface, perfect for cruising, low level racing and casual sailing.

Once the fabric is chosen, the sailmaker carefully measures and cuts the panels, traditionally on the sail loft floor, but these days benefitting from moder CAD/CAM cutting machines. Precision stitching follows, as each seam is reinforced to withstand the forces of wind and water. Unlike the heat and adhesives used in laminates, the craftsmanship of Dacron sails relies entirely on thread and needle, turning the process into a labour of love.

Customization is equally important in traditional sails. From reef points to battens, every element is tailored to the sailor’s needs. This sail will have a two-ply leech for extensive usage (many sea miles ahead) and reefs will be friction rings in lieu of the pressed or sewn ring counterparts for easier loading when hauling in a reef. While Dacron sails may lack the aerodynamic finesse of their modern counterparts, they excel in reliability and ease of handling—a testament to their timeless appeal. As the final threads are knotted and the sail is hoisted, one can’t help but admire the simplicity and beauty of a tradition all comes together.

I will make sure I post some picture of the process behind these two enthralling (well to me!) sails being made!

 

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