Build Specification Guideline

By: Andy Camarda

A sail’s construction is determined by two key factors: sailcloth type and weight, which dictate its structural integrity, and build specifications, which define the finer details of how the sail is assembled and reinforced. To ensure every sailor gets the right balance of durability and performance, we offer three levels of finishing: Coastal, Offshore, and Bluewater. Our team of expert designers then reviews each sail and customizes the finishing details to match its intended use, ensuring it is perfectly suited to the owner’s needs.

Build specifications include:

• Seam Construction: The width and number of rows of stitching on horizontal seams.
• Thread Type & Weight: The strength and UV resistance of the thread used.
• Corner & Reef Patch Size: Reinforcement added to high-load areas to prevent stress failures.
• Chafe Protection: Additional layers in areas prone to wear, such as spreader patches or lifeline contact points.
• Batten Pocket Construction: Various batten pocket styles to secure battens and reduce stress.
• Edge Tapes & Reinforcement: Strengthening along the perimeter to maintain shape and prevent stretch.
• Additional Offshore Features: Options like overhead leech lines, UV-stable thread, webbing-reinforced batten pockets, and enhanced chafe protection.

Each sail is built to balance weight, durability, and cost. While offshore sails must withstand relentless sun, salt, and high winds, coastal sails focus on ease of handling without excessive bulk.

Coastal Build: Balanced Strength for Local Sailing

Designed for sailors who primarily use their boats for day sailing, coastal cruising, and occasional overnight trips, these sails are strong and durable without unnecessary weight. Coastal sails handle the wear and tear of regular use but are not designed for sustained offshore conditions.

Features & Construction:

• Seams: 2-4 rows of stitching on horizontal seams for a strong, balanced bond.
• Batten Pockets: Choice of batten pocket enclosures (Velcro, tie-in, or RBS Rocket).
• Corner & Reef Reinforcement: Standard reinforcement to balance strength and weight.
• Edge Tapes: Standard sizing to maintain shape and durability.
• Weight Consideration: Light enough for easy handling yet durable for frequent use.

Best For:

✔️ Day sailors in lakes, bays, or along the coastline.
✔️ Coastal cruisers who stick close to shore and avoid heavy weather.
✔️ Club racers who want a durable yet responsive sail.

Not Ideal For:

❌ Sailors planning multi-day offshore passages.
❌ Boats exposed to sustained high winds and heavy seas.

Offshore Build: Strength & Durability for Extended Cruising

For sailors venturing beyond sight of land, offshore sails are built to withstand multi-day trips, sustained winds, and occasional storms. These sails are reinforced to handle the rigors of extended sailing while remaining practical for handling and storage.

Features & Construction:

• Seams: Wider and heavier-stitched seams to handle higher loads.
• Batten Pockets: Reinforced pockets to prevent battens from rubbing through.
• Corner & Reef Reinforcement: Larger patches to distribute load and prevent stress points.
• Chafe Protection: Additional layers in areas that rub against spreaders, lifelines, and shrouds.
• Edge Tapes: Heavier-duty than coastal sails to minimize stretch over time.

Best For:

✔️ Cruisers making regular overnight and multi-day passages.
✔️ Boats sailing up and down the coast or island-hopping in the Caribbean.
✔️ Sailors who may encounter heavy weather but can still access repair facilities.

Not Ideal For:

❌ Boats that only sail in protected waters or nearshore environments.

Bluewater Build: Built to Cross Oceans

Bluewater sails are designed for the toughest sailing conditions, where reliability is more important than weight savings. These sails must endure months at sea, constant UV exposure, and heavy winds without access to a sail loft for repairs.

Features & Construction:

• Seams: Maximum reinforcement with multiple rows of heavy-duty, UV-resistant thread.
• Batten Pockets: Webbing-reinforced pockets to handle extreme flogging and loads.
• Corner & Reef Reinforcement: The largest patching to distribute stress over a wide area.
• Chafe Protection: Heavy-duty protection on battens, leech lines, and all high-wear areas.
• Edge Tapes: Extra-wide and reinforced for long-term shape retention.
• Thread: UV-stable thread (e.g., Tenara) that won’t degrade over time.
• Overhead Leech Cord: An additional leech control system to fine-tune sail shape and prevent flutter over long passages.
• Added Durability Features: UV covers, reinforced grommets, and extra stitching on all attachment points.

Best For:

✔️ Ocean cruisers and passage makers crossing large bodies of water.
✔️ Boats sailing through high-wear environments with prolonged UV exposure.
✔️ Long-term cruisers spending months at sea away from repair facilities.

Not Ideal For:

❌ Coastal sailors who don’t need the extra reinforcement.

Which Build is Right for You?

Choosing the right build level depends on your sailing plans and the durability required:

Customizing for Your Needs

No two sailors—or their boats—have identical needs. That’s why our designers personally review each sail and fine-tune the finish level to perfectly match your intended use. Whether you need added durability for an upcoming passage or a lightweight setup for easy handling, we customize every detail to ensure you get the best possible sail.

By selecting the right build and working with our expert team, you’ll have a sail that lasts longer, performs optimally, and gives you confidence in all conditions.