A Sacrifice to the Sun god – replacing the Sunbrella on our jib

Since I have been exiled to life indoors while my face heals up, I’ve decided to put the time to good use and work on finishing our Sunbrella transformation.  So far we’ve replaced the sail cover, the bimini, and all of the small canvas items on the boat with new marine blue Sunbrella.   Only the jib Sunbrella and the dodger remain a moldy pacific blue.

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Sailrite has an excellent video describing the step-by-step process of adding sunbrella to your jib, but I wanted to add some little tricks I found along the way as well.

The first thing we did was spend several DAYS, not hours, removing the old sunbrella.   After breaking my seam ripper I got frustrated and googled “best seam ripper ever.”  This is when I learned that for ripping seams on heavy canvas an X-Acto knife works wonders.  This really sped up the process for us.

Once I had removed all the old Sunbrella, I started to cut the new panels of Sunbrella with a hot knife to prevent fraying.  I didn’t want to spend the extra money on the Sailrite hot knife, but I found this one at Hobby Lobby that worked very well. It also doubles as a wood and leather burner, and it has all kinds of stamp type attachments.  Pretty cool.  After using my coupon, it was only $13.

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If you’re installing panels onto a new sail, see the Sailrite video for exact measurements of panels, but if you’re re-covering a sail, it’s easier to use the old panels as a pattern.

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We set my sewing machine on the floor to keep the sail flat. This is really important when it comes to connecting the panels together.  There were a couple areas along the foot, where towards the end of the project I got tired and sloppy.  Just a small mistake can make for some very obvious bunching when the sail is up.  Next weekend I will be taking it all back down, seem ripping those seems and flattening it out.

If I was to do it again I would have done a lot more pinning.

All in all the finished product is not too bad.  It needs a bit of adjusting, like all of my projects so far, but at least it matches the rest of the canvas.

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Just for reference, the estimated cost for this project from one of our local sail lofts was $650. Although we did have to spend every evening for a week ripping stitches, our total out-of-pocket cost for the project was under $200.

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The party never stops in Galveston Bay

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We spent an action-packed weekend on the water. We headed south as soon as Mary got home form work and took a group of my co-workers out for Kemah Friday night Fireworks.

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Everyone seemed to have a great time, and two of the guys even came back Saturday to help crew the Rum Race aboard Antares.

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I hadn’t worked the winches on that boat in a while, so I was a bit rusty the first leg. However, we got everything worked out by the end of the second leg.

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That’s when we ran into Wheeee Doggie, another Cal 40, and the third leg turned into a One Design race. (We won!)

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As usual we celebrated with some rum after the race. Mary REALLY liked Doug’s last selection, so there was quite a bit of dancing later at Outriggers when we dinked over for dinner.

Sunday morning we were up early to prep Gimme Shelter for another cruise around the bay.

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Our ColdCans had arrived and worked great with their non-skid bottoms, keeping our drinks cold in 95+ degree weather.

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It was the perfect day to be on the water with winds ranging from 8 – 12 knots.

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Even Dixie Belle had a good time.

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Hanging out at the sail loft

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At the end of 2015 we decided it was time for a new mainsail. As you may remember, we did some exhaustive research on the topic.

After talking with all of the sail makers we finally decided to go with Banks Sails, both because they matched the 10% seasonal discount all the other companies were offering  and because they are the only sail loft still doing all the cutting and sewing right here in Kemah.

Trent, Keith and Chris at Banks invited us to watch them cut out and sew our sail, but unfortunately that happened the same week as Mary’s accident, so we had to take a raincheck. However, we finally got a chance to visit and watch them working on some other projects.

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Trent showed us how each sail is designed on the computer. The design is then split into panels, which are plotted onto a roll of sail cloth in a pattern that will minimize waste.

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The seams are marked and the panels are cut out on the big machine at the back of the loft.

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Then the pieces get stitched together. The entire floor of of the loft is raised to table height and the sailmakers sit in pits, which are the actual floor of the building.

We had one tiny issue with our new main. During our second time out, the slug on the clew popped out of the track.

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By the time we got back to the boat the next weekend, Banks had already replaced the slug with a larger one and added a velcro loop just as an extra precaution.

It feels good to support a local business, and we’ve been so happy with their service, they’re now helping us design a new stack pack and bimini for Gimme Shelter.

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Banks will be at the Southwest International Boat Show at South Shore Harbor March 17 – 20, so stop by and ask  Trent his trim secrets. There’s a rumor that if he’s on your boat during a rum race, you’re guaranteed to win.

What does it cost to replace the mainsail?

Gimme Shelter is a 1982 O’day, and she still has her original mainsail. Yes, our main is 33 years old and so baggy that you could probably cut a storm jib out of it, re-stitch, and never even notice the material was gone.

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Unfortunately there is no cheap way to replace a sail. Sure, you can scour eBay and resale shops for used sails approximately the same size that might be in slightly better condition, but you’re still going to spend several hundred dollars and wind up in the same boat as you were before (both literally and metaphorically).

Therefore, I’ve begun the quest for Mary’s Christmas present by contacting several sail lofts in the area and overseas. Locally I contacted North Sails, Quest Sails, and Banks Sails. We know at least one person who has had sails made by each of those shops. Nobody gave any of them absolutely glowing reviews, but nobody gave them poor reviews. It was generally something like, “Well, I wanted local support and service, so I went with X, but they measured the Y wrong the first time, but they fixed it, and it turned out really nice in the end. I’d use them again.”

Yes, we heard tales of both a strong track being mis-measured by one company and a sail cover being mis-measured by another company. Both companies fixed the issues, but on the sail cover you can definitely see where it originally ended, then they stitched on another 18″ of fabric to make it reach the end of the boom.

To give you perspective of the sail size versus cost, our current sail has a 37’4″ luff, 11’6″ foot and a 39′ leech. A quote request was made to six different sail lofts with the following specs:

  • A new cruising mainsail for an O’day 34
  • P (height of mast from boom) = 38′
  • E (length of boom) = 11.75′
  • 2 reef points
  • Bolt rope foot
  • Logo
  • Sail numbers

Here are the results we got from the local lofts:

Quantum Sails (10% seasonal discount) $2,037.09

Construction: Designed using Quantum’s, iQ suite of computational tools, constructed from Charter 7.0 CC woven polyester. Cross Cut panels are laser cut, and assembled with oversized, tear drop shaped corner and reef patches, wide seams with triple throw stitching, extra layering and extensive reinforcement of high load areas throughout, with multiple webbing straps, stainless steel rings or Rutgerson press rings at head, tack, clew and reefs.

Includes: Hand sewn luff and foot hardware, spreader patches, pre-stretch or high modulus leech and foot cords with cleats and purchase systems as necessary, telltales, draft stripes, cunningham, sail ties, drawstring sailbag, 1 Full, 3 Mid Batten Pockets, RBS Epoxy 15mm Battens, Reefs (2), 2 insignias, 4 sail numbers

North Sails (unspecified seasonal discount) $2,170

2 standard reefs, 1 full batten, 3 leech battens, cunningham, integral foot skirt, insiginia

Banks Sails $2,230 – $2,685

We’d like to thank you for the opportunity to build a new mainsail for your O’Day 34. Our Cruisemate Plus would be great performing sail for your boat. Your sail would be constructed from Dimension Polyant’s OC, CB or AP cloth. This is a superior woven Dacron material that surpasses the longevity and performance of other cloth manufactures. The biggest difference between them is that the AP has more of a UV inhibitor (like sunscreen) to help it last longer, a slightly tighter weave and the highest quality yarns available on the Market. Dimension’s QA procedures grade their yarns in 3 categories (A, B & C). ‘A’ yarns are used in the warp and fill of the AP cloth. Our prices also include custom measurement and design to provide a guaranteed fit to your boat. Additionally, unlike other lofts, you would be welcome to stop by during construction and see your sails being put together. Also, if you have any specific thoughts about the design of your sails you can talk/visit with Trent, our designer, to have input on the sail design to get the exact performance that you desire. Also removal/disposal of your old sails and installation of your new ones are included as well. We are the only loft in the area doing 100% of the work right here in Kemah!

  • Cruisemate Plus Main Sail: Crosscut Cost
  • Mainsail @ 257 sq/ft, 4 Full Battens, and 2 Reef Points
  • 308 OC Cloth @ 7.0 oz (Standard) $2,230.00
  • 301 CB Cloth @ 7.0 oz (Upgrade) $2,415.00
  • 280 AP Cloth @ 6.5 oz (Superior) $2,685.00

Here are the responses from the overseas sailmakers:

Rolly Tasker  $1,570

Standard Mainsail Coastal Cruising                                                   US$

  • 7 oz US Dacron Crosscut                                           1,168.00
  • Luff 38:  Foot 11.75:  Area 250 sq ft 
  • 2 reefs                                                                            180.00
  • Logo (both sides)                                                             60.00
  • 4 numbers both sides                                                       48.00
  • 1 sail UPS door to door USA                                          114.00

Hyde Sails Direct $1,313 – $2,915

Note: The Hyde website has a huge database of vessels, and you can just choose your boat model and then spend hours selecting fabrics and adding all the bells and whistles to your sail. The breakout below was the the Cruising Mainsail (Challenge Hi Modulus Dacron) option with full battens.
Sail Cloth: Challenge Hi Modulus HA 7.3 Dacron
Design: Crosscut
Wind Range: Usually under 20 knots, occasionally to 25
Reefs: 2
Batten Type: Tapered Fiberglass
Battens: 4 full battens
Trim Stripes: Yes
Free Shipping
$1,628.00

Then there was the Do-It-Yourself option. We also got a quote from SailRite for a mainsail kit.

SailRite (10% custom discount) $1,126.48

Obviously the big catch to this option is that Mary would have to sew it together, which means purchasing a much heavier duty sewing machine. I’m not going to make her assemble her own Christmas present, but it is worth noting that if you wanted to make your own sails, the cost of the mainsail kit and a SailRite sewing machine is about the same as having your sails made by a local loft — but when you’re finished you still have a SailRite machine for the rest of your projects.

O’Day 34 Main Kit, 8.4oz SC Dacron, crosscut, two rows of reef points, 2+2 full battens, RBS tapered E-glass batten set, leechline, boltrope on luff and foot, slugs on luff, outhaul slug at clew, P 38’, E 11.75’
Subtotal $1,225, Custom Discount -$122.50, Shipping (UPS Ground) $23.98

As you can see, the difference in price between our local lofts is negligible, $2037 – $2,230. Yes, Banks came in highest, but they bid 4 full battens while the others bid 1 full, 3 leech battens. All of them offer a 1 year warranty on their sails.

However, the mail-order sails do create significant savings — they’re almost as cheap as a SailRite kit. The scary part with the overseas sail lofts is that if it doesn’t fit correctly, I could be looking at hundreds of dollars spent and weeks of waiting to ship it back to them for alterations. On the other hand, if the mail-order sails do fit, we’d have enough money left over for solar panels or a nice chunk of change to put towards upgrading the autopilot. Is it worth the gamble?

I’m continuing my research. I have to decide by Friday if I want 4 full battens, 2 full battens and 2 leech battens, or 1 full batten and 3 leech battens. Then I have to pick a sail loft and pull the trigger.

What would you do?

Padded lifelines for a fraction of the corporate price

A few months ago Fred had it in his mind that we needed padded lifelines to spruce up the cockpit and lean back against while sailing.

Well we headed out to West Marine and found a package of lifeline pads for 62.99.

We got these “premium” lifeline cushions home to discover that the construction was so very basic we should have just made them ourselves. They were literally a piece of PVC wrapped in plumbing insulation — the stuff you put on your pipes, so they don’t freeze — with a sleeve of sunbrella.

We paid $65 for that?!!!

This month I got a bee in my bonnet to do some sewing, so I decided to make my own lifeline covers and see just how easy it was.

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After sewing the sleeves we just needed to get some PVC pipe, and some padding, and it all slid right together.

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Here’s a shot of the pads on Gimme Shelter. The top line has the West Marine pad, and the bottom line is showcasing the one I sewed myself.  The West Marine version comes only in the 57″ length and only in blue.

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For those of you without any sewing skills, you’re in luck. This week I’ve decided to launch the Gimme Shelter Etsy Store at https://www.etsy.com/shop/SVgimmeshelter.

I would be happy to sew and assemble a custom pair of lifeline pads for you in whatever length you order and in your choice of sunbrella colors for half the price of what West Marine charges.

So if anyone would like to get some lifeline covers made for their boat, feel free to order!

I’ll slowly be adding more useful and interesting nautical products to the store as I conduct this Etsy experiment in entrepreneurship, so bookmark my new site and stop by often!

At the boat show

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It was that time of year again. A time filled with magic and mysterious polishes that will supposedly make old aluminum look like new stainless. A time when “For Sale” signs appear on vessels in local marinas like buds on the trees. A time to re-stock your supply of free key floaters and drink coozies.

It’s time for the Southwest International Boat Show!

South Shore Harbor hosts the annual Southwest Boat Show in Kemah, Texas. I have to admit, having now been on many different types of vessels, the show isn’t as exciting as it was a few years ago. However, there were two big reasons to stop by this year.

The first reason was the Lagoon 450.

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Our upcoming summer charter will be on a Lagoon, but we’d never actually been on a large cat, so we were very excited to get a tour and see what they were really like.

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The 450 would definitely be a comfortable live-aboard with plenty of amenities and space for guests.

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There was no shortage of cabinets, closets, drawers, and other storage throughout the vessel.

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Call me selfish, but I much prefer the “owner’s” version over the “charter” version of these boats with a big cabin and head on one side — not that we’ll ever be able to afford ownership of either version. But maybe someday we’ll at least have a vessel with a stand-alone shower.

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Unlike some of the older, smaller cats we’ve toured like the Prouts and the PDQs, Mary had no trouble seeing over the helm of the Lagoon 450.

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Once we were finished there, we headed over to the next pier to check out the pre-owned Fountaine Pajot Lipari 41.

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The FP was also a cool boat with a very similar layout. Though smaller, it still had plenty of storage and space to entertain.

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Mary’s only complaint was that she did not like the design of the shower stall in the owner’s head. She prefers clear glass walls. I don’t know if that’s a deal breaker.

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However, she had no problem with the kitchen.

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The FP also had an elevated “flybridge” helm.

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Although on both boats, once the sails are set, it’s easy to keep watch and adjust the autopilot from inside at the nav station.

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However, the very visible escape hatches in the FP remind you of the one underlying danger of cat sailing — ending up upside down.

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Once we’d had our fill of touring boats we can’t afford, we walked through the vendor area and spent almost $40 on two burgers, fries and drinks while taking in some live music.

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And while nobody escapes the boat show for free, at least we didn’t end up with a radio-controlled boat.

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Or one of these three-wheeled slingshot cars.

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Or $99 for 20 minutes of being tethered to a jetski on a hydro-rocket.

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But there’s always next year …