ORIGINAL: marjin
3dbob,
Thanks, I'll try some of the ideas suggested. I have a lady friend, a superb seamstress, that is willing to tackle the job using the original sails for the patterns.
marjin
Unless the sails are large (M-class, 10-Rater and beyond) sewing isn't the best way, usually only doublesided tape, as used by sailmakers, is sufficient.
I only zigzag the taped joints because I sail my boat in too much wind (or with too much sail) to keep the seams together.
The outside seams are just cut with a hot, sharpened soldering iron to stop it from fraying.
The more you sew, the more baggy your sails will end up...
Regards, Jan.