Help! sewing leach line back into leach

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   The storm took my furled 
genoa and split the leach up about 20 feet. It's more complicated than I
 thought to sew it back together.

Here is a photo and a cross-sectional diagram of my leach.

There are a total of six layers.
Furling canvas (blue) is bonded to a layer of light canvas or tape. (It is marked by the silver paperlcip)
Then there's one layer of light canvas/tape, which is frayed as if torn along its length. (green paperclip)
Then there's a second layer of light canvas/tape; this one has a clean edge, as if manufactured that way - no tearing. (pink paperclip)
Finally, there's a layer of canvas/tape bonded to the sail canvas itself. (blue paperclip)All
 of these protrude the same amount - about 1/2" - from the stitching. 
This mean I can't really tell which ones are meant to wrap around the 
leach line.

I'm going to go out and buy a roll of sail tape (I 
think you get it with a crease along its length, yes?) but I don't know 
what I'm sewing together.

1] Which pair do I slip the leach line inside of?
2] Which pair or pairs do I sew together?
3] Is this too big a job for an amateur? I wouldn't want my sail to take off next time I get a gust...

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DaveC426913 Members Profile Send Private Message Find Members Posts Add to Buddy List Forum Member Joined: 23 June 2012 Status: Offline Points: 3	Post Options Post Reply Quote DaveC426913 Report Post Thanks(0) Quote Reply Topic: Help! sewing leach line back into leach Posted: 23 June 2012 at 7:31pm
	The storm took my furled genoa and split the leach up about 20 feet. It's more complicated than I thought to sew it back together. Here is a photo and a cross-sectional diagram of my leach. There are a total of six layers. Furling canvas (blue) is bonded to a layer of light canvas or tape. (It is marked by the silver paperlcip) Then there's one layer of light canvas/tape, which is frayed as if torn along its length. (green paperclip) Then there's a second layer of light canvas/tape; this one has a clean edge, as if manufactured that way - no tearing. (pink paperclip) Finally, there's a layer of canvas/tape bonded to the sail canvas itself. (blue paperclip) All of these protrude the same amount - about 1/2" - from the stitching. This mean I can't really tell which ones are meant to wrap around the leach line. I'm going to go out and buy a roll of sail tape (I think you get it with a crease along its length, yes?) but I don't know what I'm sewing together. 1] Which pair do I slip the leach line inside of? 2] Which pair or pairs do I sew together? 3] Is this too big a job for an amateur? I wouldn't want my sail to take off next time I get a gust...

MattGrant Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group Sailrite Employee - Expert Joined: 21 April 2005 Location: United States Status: Offline Points: 3012	Post Options Post Reply Quote MattGrant Report Post Thanks(0) Quote Reply Posted: 25 June 2012 at 5:06pm
	This layering makes me think the sail has one layer of sacrificial suncover material which was replaced (covered) in the past. It is not problem if it does. Basically the leech line can go inbetween any of the layers so long as it does not come out. But I think you might want to undo some stitching further up the sail to make sure the line is between the proper layers according to the rest of the sail edge. Otherwise the line will create an odd crease at a transition point somewhere along the leech. To repair the edge use a dacron tape and fold it in half lengthwise. One side should be wedged between the canvas blue suncover and the first layer of Dacron sailcloth. Then the free leg wraps around the rest of the "mess" and onto the back side of the sail where it is sewn. You will then need to sew a straight stitch right along the back edge of the sail to hold everything back together again. And ofcourse the inner edge must be secured with a stitch running through the entire assembly all along the leech. I hope this makes sense. Thanks, Matt Sailrite
	Best Regards, Matt Grant Sailrite

DaveC426913 Members Profile Send Private Message Find Members Posts Add to Buddy List Forum Member Joined: 23 June 2012 Status: Offline Points: 3	Post Options Post Reply Quote DaveC426913 Report Post Thanks(0) Quote Reply Posted: 25 June 2012 at 10:52pm
	Thanks for your help. So, to be clear, I need to sew along both sides of the leach line. Along the outer edge and on the inside of it. Do I need to concern myself with the kind of stitch? Am I to gather from your comments that this is not a load-sensitive bond? i.e. if it isn;t professional-grade I won't one gusty day find my genoa wrapped around someone else's rigging?

MattGrant Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group Sailrite Employee - Expert Joined: 21 April 2005 Location: United States Status: Offline Points: 3012	Post Options Post Reply Quote MattGrant Report Post Thanks(0) Quote Reply Posted: 26 June 2012 at 9:29am
	Yes, sew along both sides. I would just use a straight stitch in both locations (longest possible). Correct, the layering here is not original design. The norm would be to have the leech sail edge capped with a leech tape and then the sacrificial cover sewn to one side. so total thickness (outside of patching areas) would be 3 layers of Dacron and then the sacrificial material.
	Best Regards, Matt Grant Sailrite