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ALTHOUGH I BEGAN WORK on The Sailmaker’s Apprentice sixteen years ago, it would be a mess o’ galley whispers to suggest that its creation
has been a concerted sixteen-year effort. Rather, it has been an intermittent process marked by setbacks, diversions, some lucky breaks, and much
encouragement from family and friends. So fid out your earholes while I spin a bit of a yarn about the process.
I wrote the pieces of this book in pretty much the same sequence in which they now appear, although recently acquired facts, updates, and inspirations were inserted in later drafts of the manuscript. Portions of The SailmaJcer’sApprentice are reprints of material originally published in WoodenBoat magazine under my adoptive name, Malcolm Wehncke.
More recently, I became “the Sail Doctor” for a question-and-answer column in Small Boat Journal magazine. That column and other pieces reprinted here were published under the stage name and nom de plume Malcolm Howes. I then entered a whole new life by finding my birth parents, their families, and my biological heritage. I have since woven a new identity for myself that has incorporated not only my family heritages but also my chosen name, Emiliano Marino.
I remain one of the many sailors who sees sailing as a means of holding onto a natural interaction with the earth and its elements. There are sailmakers who still practice the old ways of building sails—ways that, comparatively speaking, placed humans in balance with nature. I invite you, my apprentice, to seek that balance too by taking up the needle and palm, and by ploughing the oceans of the earth under sail, hearing the wind, with wings you’ve made yourself with your own magic and your own hands.
Contents
TABLES
PREFACE
ACKNOWLEDGMENTS
INTRODUCTION
1 A Ditty Bag Apprenticeship
TOOLS
MATERIALS
CUTTING, FOLDING, AND MARKING THE CLOTH
SEWING
FINISHWORK
2 SailingHulls, and Sails
WHERE ONE SAILS
ERGONOMICS
THE HULL
HELM BALANCE
3 Rigs and Sails
RIG TYPES
THE SQUARE RIG
THE LUG RIG
THE GUNTER RIG
THE SPRIT RIG
THE SPRIT-BOOM RIG
THE WISHBONE RIG
THE FULL-BATTEN RIG
THE BATWING RIG
THE GAFF RIG
THE BERMUDAN RIG
THE LATEEN RIG AND THE SETTEE RIG
THE POLYNESIAN CLAW RIG
SAIL TYPES
WORKING SAILS
AUXILIARY SAILS
STORMSAILS
RIDING SAILS AND STEADYING SAILS
SAIL RIG CONFIGU-RATIONS
CAT RIG
SLOOP RIG
DOUBLE-HEADSAIL, SINGLE-MASTED RIGS
DOUBLE-MASTED CATS
KETCH
YAWL
SCHOONER
BIG-BOAT RIG CONFIGURATIONS
4 Sail Shapes and Theory
LIFT
SEPARATION, DRAG, AND EDGE VORTICES
SAIL SHAPE
SAIL TRIM
SAIL INTERACTION
SAIL MATERIALS AND CONSTRUCTION
5 How Sails Are Made
THE BUSINESS OF SAILMAKING
THE PRINCIPLES OF SAIL DESIGN
THE SAILMAKING PROCESS
SAILMAKING MATERIALS
THE TOOLS OF THE SAIL- MAKER
6 Making Your Own Sails
OBTAINING MEASUREMENTS
DESIGNING A SAIL
LOFTING AND SEAMING THE SAIL
INSTALLING CLOTH REINFORCEMENTS
FINISH- WORK
CHECKING OUT YOUR SAIL
SAIL ALTERATIONS AND ADIUST- MENTS
Sail Fittings: ".Hardware” and “Software”
FITTINGS WITHIN SAILS
FITTINGS SEIZED TO SAILS
RIGGING FITTINGS
Sail Care and Maintenance
PREVENTIVE MAINTENANCE
SAIL STORAGE
TANBARKING AND THE PRESERVATION OF SAILS
Sail Repair and Restoration
DAMAGE ASSESSMENT
THE REPAIR AND MAINTENANCE KIT
MAKING REPAIRS
11 Sailbags and Sailcovers
SAILBAGS
SAILCOVERS
12 Sail Handling, Trim, and Adjustment
BENDING A SAIL
SETTING A SAIL
SAIL TRIM
SAIL SHAPE
GETTING THE MOST OUT OF A GAFF RIG
SAIL REDUCTION
SAIL CONTROL AND MANAGEMENT
APPENDIX A Glossary
APPENDIX В Sailmakers, Riggers, Brokers, and Cleaners
APPENDIX С Sources of Materials
APPENDIX D Bibliography
APPENDIX E Other Sources of Information
INDEX