How to Make a Sail Cover

X-HT-300180

Protect your flaked mainsail from the sun’s harsh rays, inclement weather and more with a durable mainsail cover. The sail cover fastens under the boom with Twist-Lock Fasteners with a snap button finish to provide a clean look and reduce chafing. The cover is secured around the mast with a UV-resistant marine zipper. This sail cover pattern features pre-plotted, long-lasting Sattler fabric for easy construction. Got lazy jacks? Order the Sailrite® Lazy Jack Slit Kit for Throated Sail Covers (sold separately, #126564) along with the sail cover kit, and you can complete the mainsail cover and slits all at the same time.

Video Chapters:

Measuring Boom Length for Kit Size — 1:54 min.
Cutting Canvas on Patterned Lines — 2:46 min.
Sewing Logo — 6:52 min.
Sewing Top Edge of Panels (Spine) — 9:13 min.
Tailoring Canvas on Flaked Sail — 17:20 min.
Marking Lazy Jack Slits (Optional) — 20:48 min.
Hemming Bottom Edge — 22:20 min.
Installing Zipper at Front Edge — 25:18 min.
Cutting & Hemming Aft Edge — 31:25 min.
Creating Mast Boot Top — 35:16 min.
Creating Lazy Jack Slit Openings (If Required; Lazy Jack Kit Sold Separately) — 43:14 min.
Installing Twist-Lock Fasteners — 1:13:15 min.
Installing Cover — 1:19:39 min.

Materials List:

Sailrite® Throated Sail Cover Kit – Sattler® Fabric

Tools List:

Snap Fastener Installation Tool #25204*
Sailrite® Edge Cordless Hotknife 18V Package #122177
Precision Cutting Blade & Foot for Edge Hotknife #125495
Chalk Pencil Cartridge Set #121669
Sailrite® Clear Acrylic Ruler 6" x 24" #102400
Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine (110V) #311602
Sailrite® Ultrafeed® Industrial Sewing Table #120934
Sewing Gauge Ruler 6" #102995
Sailrite® Canvas Patterning Ruler #107040
Large Fabric/Leather Grip Clips #126365
Suisei Magnetic Sewing Guide #102983
Gingher® Scissors Right Hand Lightweight 8" #101017
Scribe-All® Black Marking Pencil for Vinyl #121977
Basic Thread Snips #123222
Sailrite® Twist-Lock Eyelet Hole Cutter #108001
Sailrite® Cutting Block & Die Holder #121597
Barry King Mallet Hammer Style 3# #68563
Prong Bending Tool for Twist-Lock & Lift-The-DOT® Fasteners #120445
Sailrite® Drill Hole Cutter 1/8" #121817
Tape Measure, Drill, Vise

*This item is included in the Throated Sail Cover Kit.

The throated sail cover is a popular design option because it snugly follows the shape of your flaked mainsail so the cover won’t catch wind, and rainwater can easily wick away from the cover without pooling. Our step-by-step video will show you how to sew your own mainsail cover.

This Throated Sail Cover Kit uses Sattler® Marine Grade Fabric. Sattler Marine Grade is a high-performance, solution-dyed acrylic fabric with a legacy of strength, longevity and affordability. Harsh outdoor conditions — including water, UV rays, and mold and mildew — are no match for this durable canvas fabric. It’s ideal for all of your marine cover and canvaswork needs. The competitive price makes it the smart choice for savvy DIYers on a budget.

Our comprehensive, step-by-step video tutorial walks you through the entire cutting and assembly process. We'll show you how to measure your boom for the sail cover kit size you need. Throughout the video you’ll learn valuable sewing skills including how to measure and mark fabric, how to hem, how to install a zipper, and more.

X Ht 300180 3 — Here's a closeup of our lazy jack slit installation. If your boat has lazy jacks, order our Lazy Jack Slit Kit as well (#126564).

Sailrite DIY kits make it easy to sew projects for your boat and beyond. The kits include all the materials you need to complete the project. All you need to supply are a sewing machine and basic tools and supplies. Our kits are a great way to save money while improving your sewing skills and learning new techniques. Click here to browse our entire offering of quality DIY kits with free video instructions.