Scott wrote:
I appreciate the spirited discussion on materials and sail construction. There is much to think about.
I got my order of POLYESTER RIPSTOP (DWR) - 2.6 OZ. I like the way it feels (for what that is worth) and it definitely sheds water very well. It seems less stretchy and stronger than other materials. I would say it is much less stretch than any nylon I have looked at and slightly less stretch than Odyssey.
Unfortunately, if I give it a little effort, I can blow air though it. It seems that a coating of Polyurethane or Acrylic or something to make the fabric air tight is a necessary feature. This fabric does not have a coating.
I will probably use this to make some bags. I can't imagine it is good to have air blowing through a sail.
It seems the supplier used straight scissors or a razor to cut the fabric. A hot knife or pinking shears would have been considerate. When I unfolded the fabric large parts of the weave came apart in a long thread.
It's not a lack of coating that should cause you to avoid this cloth. Try holding it up to a strong light - can you see pinhole-size leakage of light through it? If not, it's tightly woven enough. If it can be used for kites and tents, as the supplier claims, then it's airtight enough for a lightweight sail. It's similar to the cloth I used for my windvane, which is still strong (but faded, as it's red) after two full seasons of exposure to UV.
Yes, you'd need a hot knife to work with it. Also, V69 thread will be too heavy. Use a 100% polyester thread intended for outdoor clothing and equipment, metric size 75, Tex size T-35. On the construction, it's up to you whether you listen to Arne or to me; I'm just going to repeat that good construction methods are going to be essential to making a successful sail in a cloth this light. I would recommend a sailplan with a low yard angle to decrease stresses around the peak and throat, too. Amiina's very lightweight split junk sail has a low yard angle. Weaverbird's sail, yard angle ~ 45˚, though made from heavy cloth, is designed to minimise the loadings on the parrels, and therefore also the loadings on the cloth will be lower than with ~ 70˚ yard angle.