David,
I was intending to make our sails with a horizontal cut, each panel is one sheet, cut like the Tom Thumb drawing you have, somewhere (I've downloaded it anyway), since the Odyssey I've ordered comes wide enough. But I noticed all the shelf footed sails you've been designing have been vertically cut.
Seems like a lot more sewing for an amatuer sailmaker, is it necessary?
Gary,
It's good sailmaking practice to align the threads in the cloth to the load that is to be applied, within about 10 degrees or so. If you look at a bermudan mainsail closely, you will see that the threads are parallel to the middle of the leech, parallel to the straight line between head and clew, and at an angle to the leech near the head and clew.
In the JR, we are applying the load of the sheet via the sheet spans, at varying angles to the leech. In the lower part of the sail, there is little sheet loading, and the direction of that loading is variable. In the upper part of the sail, the loadings are higher, and tend to be in line with the leech.
That suggests to me that in the lower part of the sail, we can give more weight to other factors when choosing how to align the cloth. The chief of these is that a seam is weaker than the cloth. Using Odyssey, a panel can be made without seams, and with its weft threads at about 10 degrees to the leech, which is satisfactory on all counts.
In the upper part of the sail, and certainly in the top two panels, it becomes more important to align the cloth with the leech. With Odyssey, this can still be done with a one piece panel, at the expense of a little more wastage. However, I think it's better to lay the cloth parallel to the leech, in the top panel at least, because the head of the sail should have some rounding applied to it, and a seam meeting the head allows some broad seaming to be applied, to push the resultant camber further back into the panel. Without broad seam, that camber can lie too close to the yard (but I'm being a bit perfectionist there).
I have used the vertical cut when using polyester sailcloth, 36" / 920mm wide, because it isn't wide enough to cut a complete panel, and vertical seams are better than horizontal seams in that they can only split over a limited length; and also to be able to use the broad-seam method of adding 3D shape. Vertical cut also wastes the absolute minimum amount of cloth, when care is taken over the unrolling and cutting process.