PolySail International

High Performance/Low Cost Sails for Small Sailboats

 

 

QUICK CONSTRUCTION GUIDE FOR MAKING

LOW COST, POLY LAMINATE SAILS

 

 

PolySail International

2291 SE Gaslight St., Port St. Lucie, FL 34952-7332

Email polysail@polysail.com or call Dave Gray at 317 385-3444

PolySails–Sold on the Web since 1996. Customers in all 50 states and around the globe.

 

This page updated on 6/18/14

Overview

 

White poly laminate sails or PolySails are inexpensive polyethylene sails that are reasonably simple to construct and nearly indistinguishable from traditional sails in looks and performance--when well-constructed. Using one of our white or colored PolySail Kits and a construction process based upon our 17 years of poly laminate sailmaking experience, most customers can construct a basic, traditional sail that will get them on the water quickly and perform beyond their expectations.

 

Here’s what you need:

 

 

·         A PolySail Kit (available from Dave Gray at PolySail International (317) 385-3444 or on our PolySail Kits Page. We recommend building a sail from our quality poly laminate materials and our easy to assemble kits  rather than wasting time and money trying to find a suitable tarp and materials  from local and/or online sources who might not provide the quality you were expecting for a sail. When you purchase from us, you are buying our knowledge of appropriate material weights, stretch and resiliency characteristics of different types and thicknesses of sheet materials, reinforcing and shaping techniques specific to sail types, thread requirements, UV resistance, and many other tidbits and tips that we share only with customers or incorporate in our finished and custom sails.

 

·         A large, clean, dry, and open work space inside or out, e.g., a school gym, a golf course putting green (but not with wet or freshly mowed grass), garages (but not with oily or dirty floors), clean driveways, large decks, etc.

 

·         A long, fairly stiff steel measuring tape to lay out the sail plan. Several tapes are even better. You will also need heavy weights for holding down the material, such as the half concrete blocks I use. Outside you can use narrow tent stakes or large pole barn nails for stretching out the material on a lawn.

 

 

PolySails are constructed to take advantage of the material’s strength, stretch, resiliency, and durability. Polyethylene laminate material is all around us today in everything from those flimsy-looking plastic grocery bags that still manage to hold a gallon of milk safely to Waste Management’s Bagster that holds 3300 lbs. of remodeling trash. And, like most of today’s sails, poly laminate is a light, strong, polymer-based synthetic that can be shaped without paneling into a low cost, high-performing sail. PolySail International offers a trifold brochure that is suitable for acquainting novices with the basics of poly laminate sailmaking. Please email us at polysail@polysail.com for a personal copy.

 

 

PolySail International

2291 SE Gaslight St., Port St. Lucie, FL 34952-7332

Email polysail@polysail.com or call Dave Gray at 317 385-3444

PolySails–Sold on the Web since 1996. Customers in all 50 states and around the globe.

 

©This article updated on 6/19/2014

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ALTERNATIVE SAIL AND CORNER DESIGNS USING COLORED VINYL REINFORCING TAPE

Wa’apa Tacking Sail

Ghost: 70 sq. ft. 2.2 lb.Racing Leg O’ Mutton

Balanced Lug with 2 Reinforced Reef Lines

Bolger Oldshoe Leg O’ Mutton Main and Mizzen

Fully Battened Balanced Lug Sail

Twin Cruising Leg O’ Muttons With Windows

 

FOR MANY MORE SAIL IDEAS VISIT OUR CUSTOM PRODUCTS PAGE ON OUR POLYSAIL WEB SITE