I use cotton poplin for my sails.

Ross gave excellent advice, a truly practical guide. It's clear he's faced these problems firsthand.

Hi!
Do you have a sail plan ready? or just copy the original

I have used RIPSTOP NYLON. Totally agree with using a soldering iron. Angled chisel tip for edges. Practise on little pieces before doing the full sail cut. Pencil point tip for grommet holes. Practise on little pieces to get your grommet hole size right. Do lots of grommet holes until you are happy with the grommet and hole match up

Tape you sailplan pattern to a heat resistant flat surface and tape your sailcloth on top of that. Use lines that can be seen through the cloth.

Also, luff line on the jib:
leave enough allowance for a seam on the luff
lay double sided tape on the edge of the of the cloth, I like 4mm tape
lay you luff line BESIDE the tape
fold over the seam and contain the luff line
zig zag stitch up the seam to secure it with the luff line inside


Reinforce corners before grommet holes.⛵

Questions?

I used kite material. Cut it with a hot soldering iron to stop it fraying

Hi, I have a DF95 and want to make some sails for it, how can I go about making sails?