Joining Main Panels

1.                   Identify top and bottom of panels. (REMEMBER: shiny/dull surfaces.)

Assemble with dull surfaces inside.

2.                 Join a panel to center section. See FOOT NOTE*

Use 6½” wide panel 6½” X 76” same color as wing tips. The seam of the 6½“ X 76” strip must be aligned with C/L marked on the main panels. (Use template to orient.)

3.                 Join second panel to step #2 assembly – set aside –

4.                 Repeat step #2 and #3 with remaining 2 panels.

5.                 Now trim top and bottom of 2 main panel assemblies. Place an assembly flat on

          table, overlay template (A) over top of one side and align edges. Hot cut top

          and bottom surplus fabric. Repeat on other side. The intersection of top and

bottom tips will be approximately in center of assembly. The cut line will be

the smooth continuation of the top and bottom radius.

6.       Apply edging to the 3 radius edges. (Edging will go on over insignia cloth).

NOTE: Edging strips have color marking (ID) on one end.

          RED color strip is for center radius – 27”.

          RED color strip is also used on top radius – 27”.

          WHITE color strip is used on lower

                    radius – 42”- bottom of sail.

7. Now apply the black 3.9 oz 4” X 4” re-enforcement diagonally. The

re-enforcement is for the horizontal spar. It’s position top to bottom is in

the centerline of the center radius on the outer edge of the main sail. The

re-enforcement is only placed on the back panel assembly. Put one square on

either side of the 6½“ panel using the hem as a guide.

•  
• FOOT NOTES:

     The fabric dimensions (main sail templates) have been made to employ a ¼“ hem i.e. if you elect to use your own seam method it is OK. The design will allow a variance of dimension for this sew.

Joining Main Panels – cont.

8.     Remove (Hot-cut out) center of 4” X 4” patch with 2½“ X 2½“ metal                                          template.

9.     Sew around the outside edge of the 4” X 4” patch and inside cut out edge.

10.  Apply a 1.5 oz. 1¼“ X 75” strip to centerline of 6½“ wide stripe. Use 3M-77

(spray adhesive) to mount. Strip will be on front and back surface of each

assembly. The 1¼“ strip will go over the 4” X 4” diagonal square. Stager the

hem/seam above or below 4” square patch.

11.   Time to attach front and back panel assemblies. Place one on top of the other. A light table or window will help align both 1¼ “ black strips. Use tape or pins to hold in place. One sew either side of centerline is required. Sews must be 1” apart to allow proper pocket size for spine ferrule. (CRITICAL DIMENSION).

12.  To close and form pocket on top, fold over approximately 1½“ and sew across twice. Trim excess as needed.

13.   To prepare bottom for spar pocket, make cut across main panels approximately 2” up from bottom tip or enough to provide room for 2 eyelets to mount bungee cord for center spar. The more you remove the wider the bottom will become. Re-sew the bottom edge binding to provide secure edging. The cross cut will expose several layers of material. Locate the center pocket hole and insert two small strips of insignia cloth to either side and fold over outside edge. This will prevent snagging when vertical spar is inserted.

14.   Install aluminum eyelets o n all tips of sails and either side of center spar at bottom of main sail approximately 1½“ from bottom edge.