How to Repair Permanently Sewn-In Batten Pockets

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When inspecting your sails at the end of marine season, you may come across a batten pocket that has a tear or hole in it. Don't worry — you don't have to completely redo your sail. Instead, the step-by-step video in this blog will show you how to repair the pocket for a batten that is sewn in at the sail's leech. This DIY sail repair should take a couple of hours or less, and you'll have the peace of mind that your sail will be ready to go right out of storage next season. Let's dive in.

Materials List:

Tape Dacron® 5 oz. White 2" (Not Adhesive Backed) – #22118
Insignia Adhesive Backed UV Dacron® 26" – #126417
Seamstick 1/4" Basting Tape for Sailmaking & Vinyl (50 yds.) – #20306
5-Ply Waxed Polyester Twine Bobbin (81 ft.) – #29206
Outdoor Thread

Tools List:

Sailrite® Stainless Steel Thread Nippers – #125831
Sailrite® Edge Hotknife Package (110V) – #103800
Sailrite® Tempered Cutting Glass – #121915
Gingher® 8" Scissors
- Right Handed – #19104
- Left Handed – #19105
Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine (110V) – #311602
Scratch Awl Yellow – #235411
W Smith & Son Assorted (#13-19) Sail Hand Sewing Needles Triangular Point (5 pack) – #29112
Sailmakers Palm Adjustable - William Smith & Sons
- Right Hand – #19201
- Left Hand – #19202
Ruler/Straightedge, Pencil, Needle-Nose Pliers

Abrasion and Batten Pockets

Abrasion is a key consideration in creating a sturdy, long-lasting batten pocket. A batten shifts in its pocket as the sail moves, rubbing against the pocket and causing holes from the inside. This is especially true for the ends of the battens and for battens that have sharp edges. To combat this, we'll show you how to make a batten pocket with several layers of sturdy Dacron® sailcloth at the ends. You'll also see how to use adhesive-backed Insignia fabric as extra reinforcement.

Insignia Fabric for Reinforcement

Insignia is great for reinforcement, but that's not its only strength. This tough fabric features an aggressive glue on one side, making it perfect for emergency sail repairs. The Insignia will hold a torn sail together until you can take it down or get back to port for permanent repairs. It's easy to apply — just cut, peel and stick. Sailrite® strongly recommends that you keep your sail repair kit stocked with Insignia adhesive-backed fabric.

Sewing Your Batten Pocket

Even if you've never repaired your own sails before, you'll be able make this piece-of-cake fix with help from Sailrite. Watch the how-to video above for guidance on removing the torn material, sewing on a new patch and pocket, and sewing the batten into the fresh pocket. You can do it!

Alternative Batten Pocket Repair

This blog covered making repairs for battens that are permanently sewn into the sail. If your sail's battens are held in place with elastic, see our blog "How to Repair a Sail's Batten Pocket" for instructions on repairing that common pocket style.