We used Weathermax 80 for our prototype sails (the 'parchment' colored panels in our icon). No particular problems working with it.

We've done both; cut with Hot Knife, or scissors and finished with HK. Toss up which we liked better. 

For the last many sails, we've used dots of hot melt glue to join whatever, including homemade doubled tape (stripped and folded WM80). It's cheap, fast and easy to undo if repositioning is required, and doesn't pick up dust or grit.

Only caveat is that the dots must be pressed flat as you go, before cooling and setting up hard, so that needles can pass easily through.

Also, we find that paperclips or bobby pins make good temporary keepers that won't stick us like our pins do and are less prone to push fabric out of line (maybe our pins are dull). A sailmaker friend used staples around the edges!

Happy sail makin'!

Dave Z

Anonymous wrote:

I have only ever made one sail (a small one, with light cloth) so no advice to offer, but I wonder about this because I used lots of basting tape - basted everything -  and sewed through it all the time. Only twice in the entire job I had to a slight problem re-threading because of a little bit of glue in the eye of the needle - which took a few seconds to fix - no real problem at all. Certainly it did not cause any problem to the machine. I wonder if there are differences in the type of tape? 

Different machines respond differently to the basting tape. In general domestic machines struggle, however older type domestic 1940 - 1970 machines tend to do better. Commercial machines and the Sailrites don't seem much bothered.

You can keep the needle clean by wiping it with acetone every couple of seams.. There is also a needle lubricant called "Sewer's Ease" that helps as well.

I have only ever made one sail (a small one, with light cloth) so no advice to offer, but I wonder about this because I used lots of basting tape - basted everything -  and sewed through it all the time. Only twice in the entire job I had to a slight problem re-threading because of a little bit of glue in the eye of the needle - which took a few seconds to fix - no real problem at all. Certainly it did not cause any problem to the machine. I wonder if there are differences in the type of tape? 

I've been thinking of getting a hot knife as I've been using scissors but I hadn't thought of using a soldering iron. I must try it on a bit of scrap. I  also tried using double sided tape but the machine hated it.