25 June 2016
My IOM ( International One Meter ) “EMO” came with a much abused sails an A rig and B rig . Seldom do we need B or C rigs here . A new A rig suit costs about $160 US plus shipping & duty while the materials cost less than $10 :(O>.
In our local sailing group, mid Vancouver Island The Herbert Bros. dominate the racing with their own designs of beautiful boats . They have generously shared their data used to make their sails .
I have used this data to make a pair of camber boards on which to make my new sails.
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No 1 Camber Board |
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No 2 Camber Board – Jib only |
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Camber Board Structure |
I used some 4 x2 clear Yellow Cedar shaped across its width to exactly replicate the profile of the curves I was given and sliced it to create 6 identical ribs . The board halves are joined at 2 different angles . No 1 being 5 degrees = 2.5 degree cut on each face . The No 2 board is 10 degree = 5 degree off each face .The top surface was made from left over white counter top material. These board are probably the most demanding in terms of accuracy as they directly effect the shape of the finished sail.
From the master template drawn on Mylar drafting film I made three cutting templates out of hardboard, one for each of the the sail panels of the foresail ( jib ) Lower, mid & top and used these to cut the oversized (5mm all round ) panels out of the sail material ( see Below for Materials list ) .
In order to familiarize myself and get comfortable with the demands of the process I did a dry run using Mylar drafting film that I had on hand.
This went reasonably well, however my first seam looked a little off and because I had allowed sufficient excess material I was able to cut out the seam and redo it and still maintain the full sail dimensions.
I good friend had some ICAREX ( polyester kite fabric ) and cut me 8 x 55″ x 3/4″strips for my luff tapes . This is a hard to find material and expensive ($35/yard but does not stretch which is most important.
For reinforcement at the corner points I am trying out a patch made by hard folding a piece of sail material and attaching it with double side tape (DST) and using a clean round pointed solder iron to melt a grommet hole . Hmmm I assured by more experienced sailors that this is not strong enough so have ordered grommets and setting tools .
The first suit of sails is completed and looks good and sails set nicely . The prebend in my mast had evaporated and John offered his experience and jig to apply the appropriate pre-bend in the mast made from EASTON Tent poles . That done john further advised on re-rigging the boat at several points . The jib boom pivot – The Jib top and luff rigging – The Mast Shroud wire position and the boom location on the mast . Lastly the Mainsail Cunningham and luff wire downhaul .
Sailing tomorrow will enable me to fine tune 🙂