RE: Making sails
Thanks for the information Maylasianflyer. Will contac them.
Building a new suit of sails for my 50/500 will be a nice winter project when the snow starts hitting this December in the Moutains here in North Carolina. The 50/500 refers to the Marblehead class and was 50" long and had 500 square inches of sail. Any hull design desired. Never made sails for the smaller boats but will try and give you some guidance.
The luff of the main should form an elongated S curve with the maximum part of the S at about 1/3rd the way up and the rest gently curving back to the luff. This is where your airfoil shape comes from and also allows the head to flatten out. You can experiment to find the right amount of maximum S by using the thin double sided tape to stick the hem together temporarily and once it looks good on the boat, you can stitch the hem. If you are using battens you can add roach to the leach. S maximum to start might be 1/4" but you'll have to play with this to get the right amount to give you the right shape. Use a soldering iron with the tip ground down to a knife edge to cut the material so that it won't fray at the edges.
Generally, the same would apply to the jib. However, if you are using rip-stop, you may want much less S curve in the sails because that stuff is naturally baggy. When you hem the luff, put some cotton cord into the seam unless the sail is stuffed in a groove in the mast like some are.
Hope this will help you get started but be prepared to do it over a few times to get it right.
3dbob