diy sailboat cover

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How to Make a Sail Cover

X-HT-300180

• Measuring Boom Length for Kit Size — 1:54 min.
• Cutting Canvas on Patterned Lines — 2:46 min.
• Sewing Logo — 6:52 min.
• Sewing Top Edge of Panels (Spine) — 9:13 min.
• Tailoring Canvas on Flaked Sail — 17:20 min.
• Marking Lazy Jack Slits (Optional) — 20:48 min.
• Hemming Bottom Edge — 22:20 min.
• Installing Zipper at Front Edge — 25:18 min.
• Cutting & Hemming Aft Edge — 31:25 min.
• Creating Mast Boot Top — 35:16 min.
• Creating Lazy Jack Slit Openings (If Required; Lazy Jack Kit Sold Separately) — 43:14 min.
• Installing Twist-Lock Fasteners — 1:13:15 min.
• Installing Cover — 1:19:39 min.
• Sailrite® Throated Sail Cover Kit – Sattler® Fabric
• Snap Fastener Installation Tool #25204*
• Sailrite® Edge Cordless Hotknife 18V Package #122177
• Precision Cutting Blade & Foot for Edge Hotknife #125495
• Chalk Pencil Cartridge Set #121669 
• Sailrite® Clear Acrylic Ruler 6" x 24" #102400
• Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine (110V) #311602 
• Sailrite® Ultrafeed® Industrial Sewing Table #120934
• Sewing Gauge Ruler 6" #102995
• Sailrite® Canvas Patterning Ruler #107040 
• Large Fabric/Leather Grip Clips #126365 
• Suisei Magnetic Sewing Guide #102983
• Gingher® Scissors Right Hand Lightweight 8" #101017
• Scribe-All® Black Marking Pencil for Vinyl #121977
• Basic Thread Snips #123222 
• Sailrite® Twist-Lock Eyelet Hole Cutter #108001
• Sailrite® Cutting Block & Die Holder #121597 
• Barry King Mallet Hammer Style 3# #68563 
• Prong Bending Tool for Twist-Lock & Lift-The-DOT® Fasteners #120445
• Sailrite® Drill Hole Cutter 1/8" #121817
• Tape Measure, Drill, Vise

*This item is included in the Throated Sail Cover Kit.

The throated sail cover is a popular design option because it snugly follows the shape of your flaked mainsail so the cover won’t catch wind, and rainwater can easily wick away from the cover without pooling. Our step-by-step video will show you how to sew your own mainsail cover.

This Throated Sail Cover Kit uses Sattler® Marine Grade Fabric. Sattler Marine Grade is a high-performance, solution-dyed acrylic fabric with a legacy of strength, longevity and affordability. Harsh outdoor conditions — including water, UV rays, and mold and mildew — are no match for this durable canvas fabric. It’s ideal for all of your marine cover and canvaswork needs. The competitive price makes it the smart choice for savvy DIYers on a budget.

Our comprehensive, step-by-step video tutorial walks you through the entire cutting and assembly process. We'll show you how to measure your boom for the sail cover kit size you need. Throughout the video you’ll learn valuable sewing skills including how to measure and mark fabric, how to hem, how to install a zipper, and more.

Sailrite DIY kits make it easy to sew projects for your boat and beyond. The kits include all the materials you need to complete the project. All you need to supply are a sewing machine and basic tools and supplies. Our kits are a great way to save money while improving your sewing skills and learning new techniques. Click here to browse our entire offering of quality DIY kits with free video instructions.

Materials List:

Sailrite® Throated Sail Cover Kit – Sattler Fabric

Sailrite® Lazy Jack Slit Kit for Throated Sail Covers

Tools list:.

Sailrite® Canvas Patterning Ruler

Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine (110V)

Gingher® 8" Scissors Right Handed

Sailrite® Twist-Lock Eyelet Hole Cutter

Barry King Mallet Hammer Style 3#

Prong Bending Tool for Twist-Lock & Lift-The-DOT® Fasteners

Snap Fastener Installation Tool

Sailrite® Edge Cordless Hotknife 18V Package

Precision Cutting Blade & Foot for Edge Hotknife

Chalk Pencil Cartridge Set

Suisei Magnetic Sewing Guide

Sailrite® Drill Hole Cutter 1/8"

Sailrite® Cutting Block & Die Holder

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Make a Canvas Sailboat Cover - I Made It at TechShop

Introduction: Make a Canvas Sailboat Cover - I Made It at TechShop

Step 1: Cut Up the Existing Cover

Step 2: Make Patterns

Step 3: Cut the Large Pieces

Step 4: Sew It Together

For sewing this you can use the Industrial Straight Stitch or Walking Foot machine available at TechShop. I used a home heavy duty single stitch machine. It is borderline adequate for this job. A normal home machine will not work. Use a quality 18-20 size needle or you will be bending or breaking the needle constantly. Sew the 3 main pieces together first. Use a technique after sewing the first time called "top stiching" which is where you hold the seam down and sew back over it again. From there I sewed the bow and shroud snap edges. These are rectangular pieecs that are folded in half so that they are too layer and then sewed to the appropriate seem on the main pieces. Cut all the rectangular pieces extra long by 7 or 8 inches. Sew them on 90% of the way. Stop and fold and cut the excess off the rectangular piece, sew that seam and then finish sewing it to the main piece. This allows you to be much less precise with cutting out the smaller pieces and also allows you to not be super accurate when sewing around curved seams. I sewed the 2 zipper flap edges on. These are also again rectangles that are folded in half so they are double layer and sewn to the main pieces. Sew the zipper on. I use YKK zippers available from sailrite. In this case a 2 foot long fixed length locking zipper. Pay attention to make sure your zipper will be able to zip after you install it. I try to keep stitching around an 1/8 to 1/4 inch from the edge. If you get any closer to the zipper it may be difficult to zip it later on. When sewing on the zipper side with the pull, sew 5 or 6 inches of the zipper, you can then bury the needle, lift up the foot and you can pass the zipper pull under the foot to the area you've sewn already and then sew the remainder of the zipper on. Sew the edge skirting on. These are very long pieces. The bow sections in this case are 9 feet by 9 inches and the stern sections are 12 feet by 9 inches. For each of these I made a sub assembly by flipping the bottom seam up and sewing it and then sewing the 2 sides over. Sew these onto the main pieces. They will all be a foot or so too long. Shorten as we did for the other smaller rectangular parts. Sew a bungee cord into the bottom skirt. I used 1/4 inch bungee cord from Sailrite for this with bungee hooks and stainless steel rings. To start with you can sew one continuous piece into the bottom of the skirt. I folded the bottom skirt up about 2 inches to make the pocket for the bungee. Sew some small reinforcement pieces into the rear corners. This will help keep the corners of the boat from wearing through. Sew a reinforcement under the middle of the cover. This will be used to hold the cover up using a halyard so that water will flow off of it and not puddle on the boat. Sew a small piece of webbing onto the top in this area to clip the halyard too. Sew a small piece of velcro to the strip going around the mast. At this point you are finished with sewing and it's time to finish the bungee and add snaps

Step 5: Finish the Bungee

You will need to split the bungee at the bow and the 2 side shrouds. At each of these use a bungee hook on one end and tie a bungee ring onto the other end. Leave some extra bungee in all of these areas for now. You can tie more tension into the rings after the next step.

Step 6: Add Snaps

Add snaps at each shroud, at the mast and above and below the zipper. I used snaps available from Sailrite along with the tool to attach them. The tool is a small metal die and tap that you use to smash them in like rivets. There is an inexpensive plier like tool available from West Marine to attach these. It doesn't work well, don't waste your money on it. Either use the hammer tool or spend a lot to get the sailrite tool that looks like a large set of vice grips. Put a snap on the skirt where the bungee exists each part of the skirt. Put the snap as close to the bungee as possible. This will prevent the bungee hooks and rings from sliding into the skirt. After this you can tie the bungee cord so there is more tension.

Step 7: Put It on the Boat and See How It Fits