I have no excuse for the long pause in posting here, except: life.
|You really want to use a hot knife for this...|
I unrolled the Sunbrella on the dock, laid out the pieces using a chalk line, and cut them out using my brand new, handy-dandy hot knife (you really want to use a hot knife for this work because it seals the edges of the cut, preventing unraveling). The only tricky part of the layout was the placement of the cut outs on the side pieces for the lazy jacks. To get these right, I tied the lazy jack lines to the boom at their design locations, and then stretched a tape measure along the diagonal that the top of the sail cover will make, taking the measurements where the diagonal intersected the jack lines.
Then the depth of the cut outs needed to be established. I wanted them to be just deep enough so that the top of the cut out, which will be the bottom once the stitching to make the batten pocket is completed, would be just above that seam in the finished product. Here's the detail on that: I had determined that a 4.5" circumference would make a batten pocket large enough to accommodate the 3/4" schedule 40 PVC pipe that I was going to use as battens. Adding a 1/2" seam allowance, I struck a "fold-to" line 5" away from the top edge of the side piece. Then I laid out the cut outs so that their ends were 1/2" (seam allowance) + 3/8" (allowing for the edging to be applied to the cut outs) = 7/8" from the fold-to line.
The rest was just sewing. The cover is just shy of 12 feet long, and there is no place inside Eolian to stretch it all the way out. But sewing it over the saloon table worked out OK.
The top zipper would be impossible to operate if its aft end were not stabilized - a short strap there is seized to the topping lift line. The finishing touch is a tiny block seized to the topping lift line just above the zipper seizing - and a 1/8" line loop routed thru the block and tied to the zipper pull allows the zipper to be operated while standing on the deck, not hanging over the rail. Doing this work was interesting... I had to swing the boom out over the dock and stand on top of a ladder to reach the aft end of the boom.
I wasn't sure what I was going to do with closing off the aft end - I think I'll do nothing - the opening is not large enough to bother with.
I still need to make a front panel that wraps around the mast - the zippers that will attach it to the sail cover are already installed on the sail cover.
And I haven't yet cut the lazy jack lines to length - I think I am going to fiddle with them a little more - I want to see how things settle in with some use.
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