David Tyler wrote:

You know that saying: " build the first boat for your enemy, the second for your friend and the third for yourself"?

That sounds far wiser than my 'normal' method: Treat myself as my own worst enemy, by seriously overthinking the first boat before I start, while I'm working, and then end up re-doing half of it as I figure it out.

And yes, I learned to sew my own sails in a similar fashion. Between the split rigged main and the mizzen, I sure learned a lot about how to do it and how not to do it when I was done, and they are good enough to move the boat. (If I'd just blasted through a poly tarp first set, like David suggested, I might be better of today!)

Michael,

I get a lot of credit for my junk rigs by local sailors. When I, on request, tell them that I made the sail in my living room, their yaws drop.

Little do they know how simple it is (when I use my Amateur method B). Maybe you have had a glance on TV programs where amateurs compete in haute couture. Their skills are amazing and can kill the courage of any beginners to sewing. I promise you; the skills you need with a needle or sewing machine is less than 10% of what these hobby tailors show.

As soon as someone has taught you the basics, which is to feed the thread correctly, filling and installing the under-thread spools ( spool up 3-4 at a time to save time), and balancing the tension between the under- and over-thread, you can set to work. Make a couple of sail bags or whatever first and experiment a little with stitch length and zigzag width, and before you know it, you are in business. Surely, it takes a bit practice to get the seams straight and even since the weight of the cloth will want to pull you off the course, but a un-even seam is just about as strong  as an even one. Besides, and never forget this; the loads in the sailcloth and along the battens of a cambered panel junk sail is only a small fraction of the load in a gaff sail of similar shape and size.

Actually, I find the lofting of each panel to be more work than the sewing part. However, since I now use the practice of lofting each panel on painter’s paper, I can do any errors there, and spot them well before I start cutting in canvas. Also, remember that you only need floor space enough to loft one batten panel at the time.

If you look up how I have done it, either shown on “my” page, here or by going through the album, showing how Ingeborg’s sail was made, you will find that there are no extraordinary skills needed and no metal grommets in use anywhere. Btw, here is Ingeborg's sailplan.

Take a good look and see for yourself.

Arne

PS: If you need a bit help on the design part, just let me know, and I’ll give you a hand.

Michael - David is quite right.  If you go to a sailmaker, bearly all of them will try to make a junk sail like a bermudan sail.  It will cost you a lot of money, they will try and sell you bendy battens and it will probably need altering.  If you follow Arne's instructions, you will be able to make your own, learn a new skill, understand how the sail works a lot better and save yourself a heap of money.

It takes about 40 hours to make a junk sail, so you can do the maths yourself on labour plus materials.  Alan Martienssen managed to make two 350 sq ft sail in a friend's living room, using a hand-crank, straight stitch sewing machine.  Following Arne's methods.

However, if you insist that you can't make one, you should contact Exe Sails and Covers, who have experience in make junk sails and who advertise on the back of every JRA magazine!!!

OK, it seems a little strange that no one has used a sailmaker in the UK? That all UK members have made their own sails? Come on guys, how about a bit of help!!