How to Make a Sail Pack

email_tidbit_sailpack-cover

Are you looking for a quicker way to flake and cover your mainsail? Have you tried using a sail pack? Sail Packs are an adaptation of traditional sail covers that work with a lazy jack system to make setting and dousing your mainsail quick and easy. We’ve just released a new How to Make a Sail Pack Video and it highlights tips, techniques, and step-by-step instructions for making this popular sail cover.

Sail packs are held upright by lazy jack lines and stay in place while you sail. The pack is always open and when you are ready to lower the sail, the lazy jack lines help the sail to flake neatly in place inside the cover. This sail pack design features sleeves for battens or PVC pipes to be inserted along the top, which helps keep the cover open during flaking and reduces flutter when the sail is hoisted.

This sail pack is made from Sunbrella Marine Grade Fabric and features a long zipper along the top of the cover for quick closure and a removable forward mast boot for closing off the front of the cover. In this video you will learn how to measure your sail and pattern, sew, and install a sail pack.

 

How to Make a Sail Pack Video Chapters:

  • • Taking Measurements — 0:48
  • • Creating Cover Panels — 4:16
  • • Sewing Forward & Aft Hems — 10:47
  • • Completing Top Zipper Closure & Pockets — 15:40
  • • Sewing Bottom Hem — 25:13
  • • Starting Mast Boot — 27:02
  • • Attaching Lock Straps, Rings & Loops — 29:32
  • • Preparing Slits for Lazy Jack Lines — 40:49
  • • Finishing Cover Panels — 49:26
  • • Finishing Mast Boot — 51:21
  • • Optional Zipper Slider Control Line — 1:00:19
  • • Materials List — 1:07:21

Prefer to have written instructions? Check out our all-new Sail Cover Instructions Booklet, containing instructions and diagrams for making Sail Packs as well as Throated and Rectangular Sail Covers. Get Sailrite Sail Pack Kits containing everything you need to build a sail pack at www.sailrite.com.

Do you use a sail pack? Tell us what you love about it in the comments!

14 comments
  1. George Chamberlain said:

    For now we are using a traditional sail cover. Our lazy jacks are a Sail Care kit – they have a mix of line and bungee, and they can be drawn forward to lay along the mast and boom when not deployed, so they do not chafe on, or restrict, the sails (main and mizzen). Can the lazy jacks be rigged that same way with the sail pack, or are they always “deployed” around the sails when the sails are hoisted?

    • Nikki said:

      George- You absolutely can use a sail pack with lazy jacks that collapse. That just means that when they collapse the sail pack will be unsupported, so you will have to fold/flake it and secure it in some manner while you are sailing.

  2. Caryl Hunt said:

    This is our second year with a stack pack. What a fantastic piece of equipment. We have had lazy jacks and the next boat came with Dutchman system. This boat came with stack pack and is the best of them all. No more storing sail cover. Sail flakes into pack and you just zip it up and go. Wish you had this before we sold the last boat. I would still own it.

  3. Cindi Petersen said:

    We have the Dutchman setup, will your sail pack work with it?

    • Nikki said:

      Cindi– The Dutchman system won’t get in the way of the sail pack, but it won’t support the pack. You will need to install lazy jacks to support the sail pack, which is a somewhat redundant system.

  4. David said:

    My sail does not have any spaces between it and the boom. A rope within the sail hem slots into the boom. Is there a modification which would work with this type of sail

    • Nikki said:

      Hi David,

      Yes, there are actually a few modifications options that would work for you to use a sail pack. You could: 1. Cut slots in the foot tape edge on your sail, just above the bolt rope with a hot knife. Then the sail pack attaches through the sail. 2. Add slugs to the sails’s foot edge, allowing the sail pack to attach under the sail. Or 3. Attach supplemental tracks for the sail pack to the sides of the boom.

      We’ve also had a customer tell us that they’ve had luck with putting tabs of Dacron in the track along with the bolt rope as the sail is being fed in. The tabs have twist-lock fasteners on each side that attach to the bottom of the sail pack sides.

      Hope one of those methods works for you!

  5. Ella McCulloch said:

    I love my stack pack system. However the zippers only last about two years. I don’t have a machine so I have to send it back to the canvas maker AGAIN. What do you think about closing the bag with velcro instead of a zipper? The first zipper just failed. The second one got a worn spot on the stern end, now has broken teeth there and the pull won’t go on.

    • Nikki said:

      Hi Ella,
      We don’t recommend using Velcro on a sail pack. A good zipper will actually outlast Velcro in a tropical setting. When we made sail packs, we try to leave a hem of fabric long enough to cover the zipper, to provide it some UV protection. You could ask your canvas maker for that.

  6. Stephen Ss Soult said:

    Thanks I am taking on my first boat reiteration project. Your video have been able to stear me away from some costly mistakes

    • Nikki said:

      You’re welcome, Stephen! Good luck on your renovation. We’d love to see photos when you’re done!

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s

%d bloggers like this: