My sail gets a window

Intensity Sails sells super-cheap, but good quality sails for small sailboats. They used to sell the main for Hobie AI/TIs, and as I recall, it was less than 1/3rd the price of the official Hobie version.

I got one of the sails, and I've used the sail a few times, but there is no window, which makes it hard to see obstacles in front. Now that I have a sewing machine, I decided to add a window (and I'll also replace the window on my older AI sail, since it's getting hard to see thru).

I bought the window material, known as X-Ply, from Sailrite, and followed the directions on a Sailrite video. Here are some pictures.

1) The original sail
2) X-Ply window material
3) X-Ply rolled out on the sail
4) X-Ply cut to size

(continued in next post in this thread)

5) X-Ply basted (using double-sided tape) to the sail
6) Sewing (it's not easy dealing with a large sail in a small space)
7) Window sewed on, with 2 rows of straight stitching all the way around
8. Finished

I plan to add a second window in the white section to the left of the window in the final picture, but sewing that crinkly sail material was giving me a headache (or maybe it's just a hangover from the Doormat Derby...), so that'll have to wait until tomorrow...

I've used the sail a few times, but there is no window, which makes it hard to see obstacles in front. Now that I have a sewing machine, I decided to add a window (and I'll also replace the window on my older AI sail, since it's getting hard to see thru

Nice. I have been considering a larger sewing machine for some projects.

I've used the sail a few times, but there is no window, which makes it hard to see obstacles in front. Now that I have a sewing machine, I decided to add a window (and I'll also replace the window on my older AI sail, since it's getting hard to see thru

Nice. I have been considering a larger sewing machine for some projects.

Mine is an older (1970s-era, I believe) Singer industrial machine. Previously, I'd only used it on multiple layers of very heavy material (making trampolines for my AI)--so thick that the machine would sometime struggle, especially when reversing. In comparison, this was like sewing air...

Not sure if you posted up sewing machine info previously?

Not sure if you posted up sewing machine info previously?

I posted some info here:

https://www.norcalkayakanglers.com/index.php?topic=103765.msg

So far I've only made 4 or 5 trampolines (tweaking the design each time, trying to achieve perfection, although I'll settle for "pretty good") and the sail mod in this thread.

I also have some 4 oz dacron (in orange, of course) that I plan to use to make a new jib. That's a bit tricky though, as I have not yet figured out how to cut the cloth so as to get the exact "belly" in the sail that I'm looking for. There is some free software that will supposedly produce the patterns, but I can't seem to get it to install on my computer...

Not sure if you posted up sewing machine info previously?

I posted some info here:

https://www.norcalkayakanglers.com/index.php?topic=103765.msg

So far I've only made 4 or 5 trampolines (tweaking the design each time, trying to achieve perfection, although I'll settle for "pretty good") and the sail mod in this thread.

I also have some 4 oz dacron (in orange, of course) that I plan to use to make a new jib. That's a bit tricky though, as I have not yet figured out how to cut the cloth so as to get the exact "belly" in the sail that I'm looking for. There is some free software that will supposedly produce the patterns, but I can't seem to get it to install on my computer...

Thxs !!

Nice……no issues punching through through the x-ply? 

Keep them projects comin.

Looks good! You’ll be able to get a better view of antagonistic sea lions as they circle

I'm finding your AI projects more interesting after sailing my AI for the first time the other day. You are my AI mentor.

Looks good! You’ll be able to get a better view of antagonistic sea lions as they circle

On second thought, I think I'll remove the window and wear a blindfold...

Nice……no issues punching through through the x-ply? 

Keep them projects comin.

This was super-easy to sew thru. The trampolines I made were a different story. In some spots, the last iteration of my trampoline was 1/4" thick (tramp material folded over 2x, plus I had couple of layers of plastic-like cloth at the edges) and barely fit under the walking foot. The machine got thru that, but reversing was too much to ask.

Here is my latest--replacing the opaque "window" on my old AI sail, as opposed to installing a new window on a new(ish) sail. Removing the stitching was a major pain. Hopefully, I can get the sewing done tomorrow.

Next up, I want to make a sail from scratch--I've got the material and know what I want to do, but I'm still stuck at the design stage. I've got a book on order that should have enough details so that I can get going on that...