Mending a torn sail at sea – are you prepared for all sailing calamities?
Posted by Iryna on August 10th, 2011
Nobody expects to have a problem at sea but it’s best to be prepared – who knows what a change in sailing conditions will bring. Here’s what happened when I had a repair job at sea to contend with recently.
Since we took delivery of Totemic, our Jeanneau 53 sailing yacht used for company staff training, I’ve tried to ensure we have a good selection of tools and spare parts on board in case we need to make emergency repairs at sea.
We’ve got a range of hand tools, a cordless drill, cordless dremel, screws, washers, nuts, bolts, tapes, glues, and more. Most of these have their obvious uses, however one that I didn’t expect to use was the sail repair kit.
During one of our training weeks we sailed from Cagliari in the South of Sardinia along the west coast to Alghero in the North West of the island. Our first night was spent on anchor just off Campulongu because our intended destination of Marina Capitana had no spare visitor berths for the night.
The following morning the wind was very fresh and seas were heading towards moderate. We set off with a reef in both the main and the jib. Once away from the protection of the land the winds increased and the sea state deteriorated. Totemic sailed beautifully and even our novice sailors felt safe and reassured.
But later in the day the wind became very unpredictable, suddenly dropping and minutes later blowing at 25 knots. We went through a cycle of putting reefs in, only to be shaking reefs out minutes later. Unfortunately all this activity stressed the leach tape on our Genoa and we could see it was damaged in three places. We furled the Genoa away for the day to save it from further damage.
Next day we decided to rig and use the storm jib instead. This was a useful exercise since it had never actually been used before but made the yacht very unbalanced needing large amounts of rudder to hold course.
The following morning I woke early to find there was no wind at all. I woke some of the crew and we took this opportunity to take off the Genoa. This involved unfurling the whole sail before it could be dropped to the deck. We laid the sail out as best as we could and removed the loose pieces of tape. We then used Gaffer Tape to repair the missing areas. The repair didn’t look perfect but luckily the winds were gentle so while our repairs gradually failed, we did manage to sail all day without further damage.

The next morning we were up early to remove the sail again. This time we were in a very nice marina with Astroturf on its pontoons! This meant we could lay out the sail fully and put two overlapping lengths of Gaffer Tape all the way along the leach of the sail and six stitches every meter to help strengthen the repair. We were very proud of our work, managing to get the sail back on just as the wind started to get up.
This repair lasted a whole two days, allowing us to sail some 90 miles and to reach our destination of Alghero. Eventually the tape became unstuck but none of our stitches gave way – what a piece of handiwork and what a success!
In Alghero we found a sail maker who took the sail to his loft and replaced the whole of the leach tape for the very reasonable price of €300.
Working as a team to solve problems at sea was a challenge enjoyed by everyone in the sailing group; our sail repair kit had proved its worth; and we had all learned how important it is to be able to undertake repairs at sea.
So the motto is – don’t panic, just be prepared for any sailing eventuality!
Happy sailing
Jonathan Green
Skipper, Totemic
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