David Tyler wrote:
Daniel Collins wrote:
Ok... so that leaves another question: How do I secure the leech end of the batten pocket? A doubled-up square patch over each?
You might get as many answers to this as there are junk rig sailors, but I've always found that closed pocket ends chafe through from the inside. I like to bolt the batten through a grommet in the sail, so that the aft end is firmly fixed flush with the leech. A 5/16" bolt through a number 2 spurtooth grommet would be about the right size.
Ok, I'd already done a few of them with a tab over the pocket end (so there are 2 layers of fabric on top, the pocket itself and the tab as a doubler). The webbing attachment for the sheets goes over that, a la PJR. There are 5 layers of fabric at the sail on the leech as well so if the pocket ends start to chafe through I can always revert to banging a grommet or two in as a fallback later. I plan to wrap the batten ends with some padded fabric and duct tape before I stuff them in to hopefully minimize the possibility of chafe, but of course one always has to pay up eventually.
I'm definitely doing the bolt and grommet at the luff.
Regarding rounding, I did the lower three panels on each sail as one "unit" similar to Kurt's method of construction - I could fit that much at a time on the floor here. I rounded the top and bottom of each of those sections, as well as the individual panels stacked above, by 3/4"-1". It's not a lot, but it does make a noticeable bit of broadseaming effect so that will hopefully do what you mentioned, David, and balance the fabric out without making anything baggy or wrinkled. I did the best I could to ensure even tension along the seam and pocket lines all along the sail, but you know it's a homemade sail so there are minor imperfections throughout. I'll upload a picture of the main shortly!