What Do I Need to Start Sailmaking & Sewing Sails?

Our company is founded on DIY and the idea that making it yourself saves money and gives you an appreciation of the sail design and construction process. Plus, you get the added benefit and accomplishment of being a self-reliant sailor. We hear from many customers that learning how to sew their own sails has helped them gain a better understanding of sail design and construction — and of sailing in general. You too can become an even better sailor by understanding how a sail is constructed.

Here are the most essential tools and supplies our sailing experts recommend for sailors who want to start sewing and repairing their own sails.

11 Must-Have Sailmaking Tools & Supplies

Zigzag Stitch Sewing Machine

Let's start with the biggest investment in your sailmaking journey: a high-quality sewing machine. To sew sails, you need a sewing machine that's designed to handle multiple layers of sailcloth, webbing, vinyl window material and more. A sewing machine that can sew zigzag stitches is a must-have for sail construction. Sewing sails with a zigzag stitch is the preferred method, as zigzag stitches distribute the strain across standard overlapping sail seams better than straight stitches. Zigzag stitching also contains the raw edge of a seam better given its wider sewing path.

The Ultrafeed^® LSZ Sewing Machine sews both straight and zigzag stitches and was specifically designed with sailors in mind. The Ultrafeed's all-metal internal components are robust and powerful. The machine's cast iron body is impeccably built to the highest standards, guaranteeing quality stitching for the lifetime of the machine. And best of all, the Ultrafeed is portable. You can sew sails at home or at the marina, and then take your machine on board for sail repair and patch jobs while at sea. Given the machine’s compact, portable size, we recommend it for general sailmaking for boats up to and around 35 feet in length.

Read our blog “Why Choose an Ultrafeed?” to learn more about the Ultrafeed.

Spur Grommet Installation Tools

Spur grommets are used to create strong attachment points in sails. Depending on the size of your sail, they can be used for slugs, jib hanks, reef points, corner points, lacing, brailing lines and more. To set a spur grommet in your sail, you need five items: a cutting mat, hole cutter and mallet to first cut the hole. Then you need your spur grommet components and die set to install the grommet.

The size of the spur grommets and coordinating die set will vary depending on your sail. Sailrite spur grommet die sets will last a lifetime with proper care and use. Our well-built, sturdy hole cutters will feel secure in your hand. Using a mallet over a standard hammer is recommended, as a standard metal hammer will damage the head of your hole cutter over time.

Sailrite® Edge Hotknife or Edge Cordless Hotknife

A hotknife is an essential sailmaking tool. A hotknife cuts and seals synthetic fabric, webbing and rope so your material will never unravel. Hotknives are required for sealing webbing ends, rope, sailcloth corners and more. Using a hotknife at sail corners melts the multiple layers of sailcloth together, keeping the assembly from separating at the edges and becoming ragged. Choose between the original Edge and the Cordless version, depending on whether you see yourself working on your boat or at the marina versus in a designated sail loft or workshop with available power outlets.

Sailrite® Cutting Block & Die Holder

When cutting holes for grommets and eyelets, you need to protect your work surface with a cutting block. The Sailrite Cutting Block & Die Holder is a great choice. It features two cutting surfaces — a hard, durable plastic and a resilient rubber cutting pad — so you can choose which is best for your particular application. Plus, its compact size makes it easy to store in a toolbox or on your boat.

Dacron® Non-Adhesive Backed Tape

Dacron tape is used to finish and protect raw edges of a sail and to repair rips and tears in mainsails, jib sails and genoas. Non-adhesive Dacron tape comes in either flat or prefolded options. The prefolded tape is folded in half down the length, which makes it easier to use on sailcloth edges. The tape is made from long strips of Dacron sailcloth cut with the grain so that there is very little stretch. We carry a selection of tape widths in both non-folded and prefolded styles.

Hand Sewing Needles & Waxed Twine

Hand sewing needles by W Smith & Son are the best sailmaker's needles on the market. They are forged from cast steel and feature triangular points and sharp edges that easily cut through thick layers of sailcloth. We sell assortment packs with a range of needle sizes for a variety of hand-sewing applications.

Waxed twine is essential for hand sewing sails. We have waxed twine in both round and flat constructions. The wax coating on the twine gives the material extra weather resistance, which is an added benefit for sailmaking. Using waxed twine (versus unwaxed twine) also reduces chafe during sewing. Flat twine constructions lie close to the sailcloth to minimize snagging.

Adjustable Sailmaker's Palm

Even if you own a sewing machine, there are certain areas on a sail that will require hand sewing. Sailmaker's palms are often used for rope work and sewing areas on your sail that are too thick for a sewing machine, or areas where the machine can't reach. Another common use for palms is hand sewing a corner ring, which can often involve sewing through multiple layers of sailcloth and webbing.

Gingher® 8" Scissors

A toolbox basic, every DIYer should have a pair of sharp, high-quality scissors. These knife-edge scissors will cut sailcloth like a dream. The sharp, precision-ground blades cut through multiple layers of fabric easily. The bent handle makes cutting on a table or on the ground very easy and comfortable. They work great on slippery nylon and Dacron sailcloth.

Scratch Awl

Think of a scratch awl as an extra hand. You can use a mallet to punch it through fabric on an expendable surface to keep the fabric assembly in place. A scratch awl is also used to prepunch holes in a thick sail assembly for hand sewing. It's extremely difficult and possibly dangerous to push a needle through thick sailcloth assemblies without prepunching holes first. This is necessary for brass ring or eyelet installations in sail corners.

Seam Ripper Deluxe

Needing to rip out stitches is an inevitable part of the sewing process. Whether you have to correct a mistake, replace a vinyl window, remove a sail patch or more, you'll need a quality seam ripper. The Seam Ripper Deluxe is a small but mighty tool. Use it to rip open several feet of zigzag stitches in just seconds! This seam ripper features a very narrow beak and a protective ball on the hook to help prevent cutting the sailcloth. The flat handle prevents the tool from rolling away and the clear cap keeps both the sharp end and your hand protected.

Other Sailmaking & Sail Repair Supplies

In addition to the recommended tools and supplies listed above, you'll need a variety of other materials to sew and repair sails. Sailcloth, thread, vinyl window material and pieces specific to certain sail types (slugs, slides, shackles, headboards, etc.) are all things that you'll want to order on a project-by-project basis. The list of items below are all things you should always keep on hand for your next sail project.

Materials to Keep on Hand:

• UV Treated Polyester Thread
• Seamstick Basting Tape for Sailmaking & Vinyl (1/4" – #20306; 3/8" – #659; 1/2" – #20307)
• Seamstick 1/2" Mylar/Kevlar® Basting Tape for Laminate Sailcloth (#451522) 
• Repair Tape Dacron® (#2353)
• Ripstop Repair Tape
• Sailmaker's Leather
• Webbing

Did you know that Sailrite got its start in 1969 by only selling sail kits and instructions? Needless to say, we know a thing or two about sailing and sailmaking. And we’re happy to pass on our decades of knowledge and experience to our customers. We hope this comprehensive list has answered some of your questions and helped you determine what tools and supplies you’ll need to order. If you have any questions or need advice on sewing sails, don’t hesitate to contact us. You can post a comment below, call or email us. We’re always happy to help a fellow sailor!