How to Install Prefabricated Boltrope on a Sail

This video is brought to you by Sailrite.
In this video we will be showing you how to install a prefabricated boltrope on the foot
of a sail. This prefabricated boltrope is used along the luff or foot edge of a sail.
After watching this video you should be able to easily install this prefabricated boltrope
from Sailrite. If you sail requires a size reduction you
can cut the old edge tape and rope off and replace it with this prefabricated boltrope.
Or if you have a roller furling genoa that you want to convert to a hank on sail you
can cut the continuous support tape or luff tape off and replace it with this boltrope
for a tougher luff rope with hanks. On this mainsail we are installing the prefabricated
boltrope to the foot edge and also the luff, were going to show installation on the sail’s
foot. The prefabricated boltrope should be cut about 3 feet longer than the sail’s edge
length, this extra amount will be used to pull the rope to perform the appropriate rope
reduction for better sail performance. To help hold the prefabricated boltrope in
place along the sail’s edge we will use seamstick or double sided tape on both of the inside
edges of the folded 8oz Dacron tape. Angela will position the folded tape’s edge so it
is right up against the raw edge of the sail and then she will baste one side in place.
She is pulling off the transfer paper of the seamstick to reveal the glue about every 3
feet then positions the tape and presses down firmly to bond the seamstick to the sail’s
edge. Once the first side of the prefabricated boltrope
is stuck to the sail she will check her work to be sure the edge of the sail is pressed
up firmly to the inside folded edge of the tape. Angela uses her smart phone’s flashlight
to easily see thru the multiple layers of fabric. If she sees a flaw she will correct
it. Now that she is happy she will peel off the
transfer paper on the opposite side of the prefabricated boltrope and stick that side
down to the sail. In some applications the prefabricated boltrope
may be stapled to the sail’s edge rather than using seasmstick, but that requires a special
stapler with a high rise clincher. The high rise clincher will allow you to staple over
the boltrope. If you are performing a lot of these applications you may want to consider
purchasing that stapler from Sailrite. It will save you time.
We are ready to sew the prefabricated boltrope to the sail’s edge. We will sew two rows of
a zigzag stitch with the Sailrite Professional 4 point Long Arm Sewing Machine. This machine
sews a 3 step or sometimes called a 4 point zigzag stitch, but a standard 2 point zigzag
is also acceptable. Today were sewing this sail for an Alberg
30 with the Sailrite Professional Long Arm Sewing Machine. This sewing machine sews a
4 point zigzag stitch which is a production time saver, it reduces the amount of zigzag
stitch rows required per seam. This sewing machine has a 20 and a half inch long arm
making it easy to sew larger boat sails without having to tackle scrolling up fabric to get
it under the arm of the sewing machine. This machine is set up with the MC-SCR power system
with the Power Plus Balance wheel for optimal power and slow speed control. The Sailrite
Professional Long Arm Sewing Machine is available from
Now that the first row of zigzag stitches are done, we just need to place another row
of zigs which will fall a little closer to the boltrope.
Angela is using a hot knife to seal the end of the boltrope and tape. To finish the installation
along this foot edge we need to perform a rope reduction for optimal sail performance.
To accomplish this we need to first whip the rope at one end using pre-waxed twine and
a hand needle. We find it easier to use an awl to pre-punch holes in the sleeve which
houses the boltrope. These holes are spaced about a half inch away from each other. We
will create 5 or 6 holes. Notice that we are using two awls one holds the rope in place
at the extreme end until the whipping is started. We are using the premium cutting block on
the backside of the sail so we can punch the awl thru the sail and not damage the table
below (not that matters for our loft, but it may for you).
Next just use pre-waxed twine and a hand needle and whip the end of the rope securely inside
the sleeve. This stitch is sometimes called a sticking stitch.
When the stitch is complete just create a knot in the end of the twine and then use
a hot knife to create a button on the end of the twine, as shown here in the video.
The rope is now securely fastened at this end. At the opposite end we need to slit open
the extra prefabricated boltrope to gain access to the rope inside the sleeve. Then we need
to mark the rope at the exiting point with a pencil. We will be pulling out 1 inch of
rope per 10 feet of length. This sail at this clew corner will include
an outhaul slug so the boltrope is being cut back to accommodate for that fact. If yours
does not include an outhaul slug your rope would end at the corner of the clew. Here
is a look ahead at the outhaul slug installed. Here you can see we are marking the rope with
a pencil. Now we need to pull out that 1 inch of rope per 10 foot of length. Angela is going
to use an awl at the other end, but a second helper may be used instead of punching a hole
in your table. And then just simply pull on the rope until it equals the amount required
for the length of your sail. Now simply whip the rope in place at that
location using the same technique as used previously. We will not be showing this whole
process since it was shown earlier. That is all that is required to install a
prefabricated boltrope on a sails luff or foot edge.
Coming up next is the materials list and the tools that we used to secure this prefabricated
boltrope. Here are a few video clips of the finished
sail with the prefabricated boltrope secured and the finial hardware installed.
For more free videos like this be sure to check out the Sailrite website or subscribe
to the Sailrite YouTube channel today. It’s your loyal patronage to Sailrite that makes
these free videos available, thanks for your loyal support!

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