Ah, Jami.  I'm sorry to hear this.  I cut out a whole panel wrong on FanShi's sail!  Fortunately, I could use it for the pram hood (which now needs replacing because it is covered in grey mildew and looks disgusting.  Weathermax 80).  You know you could possibly get away with making the jiblets out of offcuts sewn together, if you are short of fabric.  Just flat seam the cloth together and then cut out the jiblets so that the seam is least disadvantageous.  Nor perfect, I know, but then, nor is missing out a sailing season! 

Remind us what cloth you are using and what you need.  Somebody might have something similar left over, that they could give you.

Jami wrote:

So, what next?

a) Rip the hinges and make new, gradually lengthening hinges. Pros: easiest and the jib seams stay intact. Cons: a 10cm gap between the jib panel and the batten at the leech.

b) Rip the hinge system and sew an extension to the lenses, sew the hinges back. Cons: using a ripped seam by sewing it again might result in a weak spot. More work.

c) Rip the hinge system and also the lenses from the jib panels. Cons: the weak spot moves to another place. Even more work.

d) Start from scratch.

Any voters?

I might go for b). If I could afford it, I'd go for d) because I hate ripping seams. But first I need to de-rig the jibs tomorrow.

After rigging and a 30min test sail it seems that I have made some kind of a measurement error with the jibs. I feel the sheeting angle is something like 1% instead of the intended 12%.

So, a de-install and some re-sewing is needed. 

This one doesn’t seem to be my season :(

EDIT: After measurements it looks like that the worst option has happened. For some totally unexplained reason during the depressing winter months I have made a severe mistake when measuring/drawing the jib panels. The lenses are correct, but the panels are way too narrow vertically. And since I don’t ever seem to learn to double-check anything, the error has been multiplied to all of the jibs and wasn’t noticed until the sail was rigged.

If the error had been made to the jib lenses, I might have been able to correct it by making adjustments to the hinges. Now I have to start from scratch with the jibs, and I have no idea if I have the money or the energy. And yes - the earlier jibs have already been scrapped.

This really, really isn’t my season.

EDIT 2: Also, math isn't my superpower. After checking everything again, it's clear that the error is in the lenses, after all. I have drawn the lens curves themselves with Slieve's 1,414 multiplier, but not drawn the sheeting angle to the lenses with this multiplier. The end result is that the jib lenses have the right curve, but essentially the same amount of sheeting angle as the jib panel. This has left me with a jib with a leech that has the same length as the luff. 

So, what next?

a) Rip the hinges and make new, gradually lengthening hinges. Pros: easiest and the jib seams stay intact. Cons: a 10cm gap between the jib panel and the batten at the leech.

b) Rip the hinge system and sew an extension to the lenses, sew the hinges back. Cons: using a ripped seam by sewing it again might result in a weak spot. More work.

c) Rip the hinge system and also the lenses from the jib panels. Cons: the weak spot moves to another place. Even more work.

d) Start from scratch.

Any voters?

Good on you Jamie, and thanks for sharing the information. I hope when it is done you are pleased with the result.

I have now started sewing new jibs with 1100 mm chord, 10% camber and 12 deg sheeting angle. I will also make a new, continuous top panel. It’s very, very interesting to see the difference as soon as the sea ice melts in the spring.