How to Install Prefabricated Boltrope on a Sail

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If your sail requires a size reduction, you can cut the old edge tape and rope off and replace it with prefabricated boltrope. Or, if you have a roller furling genoa that you want to convert to a hank-on sail, you can simply cut the luff tape off and replace it with prefabricated boltrope for a tougher luff rope with hanks. This video will walk you through the steps required to install this prefabricated boltrope on the edge of your sail.

Video Chapters:

Basting & Sewing – 0:19 min
Whipping & Rope Reduction – 3:43 min
Materials List – 6:50 min

Materials List:

Prefabricated Boltrope Tape 5/16" (#100379)
Seamstick 3/8" Basting Tape for Sailmaking & Vinyl (#659)
Tex 90 (V-92) White UV Bonded Polyester Thread 4 oz. (#100079)
5-Ply Waxed Polyester Twine Bobbin (#29206)

Tools List:

Sailrite^® Ultrafeed^® LSZ Walking Foot Sewing Machine (#311602)
Sailrite^® Edge Hotknife Package (#103800)
Scratch Awl Yellow (#2354)
Sailrite^® Rubber Poundo Board 12" x 12" (#123962)
W Smith & Son Assorted (#13-19) Sail Hand Sewing Needles Triangular Point (5 pack) (#29112)
Scissors, Pencil, Tape Measure

Install prefabricated boltrope

It only takes a few tools and supplies to install prefabricated boltrope onto your sail. You’ll need everyday supplies like basting tape, UV resistant thread, twine, a scratch awl, scissors and hand-sewing needles, among other basic items. One thing you won’t be able to do without is a zigzag stitch sewing machine. You’ll need to sew the boltrope onto the edge of your sail with zigzag stitches. In our video, we’re using the Sailrite^® Professional Long Arm 4-Point Sewing Machine. It’s a professional, industrial machine capable of both 2-point and 4-point zigzag stitches, as well as sewing a straight stitch. Though we are using the Professional, this project can also be done with the Ultrafeed^® LSZ Walking Foot Sewing Machine.

In this video, you’ll learn how to cut the prefabricated boltrope to the right size for your sail. You’ll also learn how to baste the boltrope to the edge of your sail. We sew two rows of 4-point zigzag stitches along the edge of the boltrope, though you can sew two rows of 2-point zigzags (like the Ultrafeed does) without issue. Next, we’ll show you how to perform a rope reduction at the foot edge of the sail for optimal sail performance. Finally, we’ll finish up with whipping the end of the rope securely inside the sleeve using waxed twine and a hand-sewing needle.

That’s all there is to it! How did your project turn out? Let us know if you have any questions or if there’s anything we can do to help. We’re always happy to answer any questions and help our customers get back on the water and enjoying their sailboats!