A sail came in this morning that serves as a perfect example of what to look for when inspecting an older sail. Initially, it was clear that this sail would need considerable work, potentially exceeding the value of the investment for the owner.

My inspection process starts at the head, examining the head webs or headboard for signs of UV damage and chafe. Moving on, I assess the clew and tack webs. Interestingly, the head webs in this sail had been competently replaced and covered with UV-resistant material. However, the tack and clew webs told a different story. They showed significant wear, including broken stitching and extensive chafe. Notably, there was substantial UV degradation. I noted the need for web replacement on my inspection sheet.

Next, I evaluated the luff. This sail had a #6 luff tape with a Teflon wrap, which was in surprisingly good condition, requiring no immediate attention. However, the foot and leech displayed considerable UV damage. I looked for signs of cracking in the leech and foot tapes, along with chafe and UV deterioration. The stitching on the UV cover was also severely compromised and in need of restitching.

Inspecting the edges, I then thoroughly examined both sides of the sail for broken stitching, chafe, and holes. This particular sail was built the old-fashioned way, designed and lofted directly on the loft floor instead of using computer-aided design and cut panels. The broad seams featured narrow zig-zag stitching, unlike the modern triple throw stitching. Also, the corner patches were slab panels rather than the more effective radial patches that distribute load more efficiently. I have built sails using these traditional methods for clients seeking a classic aesthetic, but it is labor intensive and creates a less predictable shape.

In conclusion, any restoration work on this sail, likely around 40 years old, would be a case of spending good money on a diminishing return.

For an honest and professional evaluation of your sail, please don’t hesitate to give us a call!