The sails arrived and they look amazing!  Thanks to Rod Carr, of Carr Sails . He does very nice work. And he is more than happy to work with you too. He truly wants you to like his sails, and he wants his sails to both look good and perform well. Use him for your next set of sails. He's threatening to retire from sail making in the next few years, so either get your sails soon or try to convince him to stay in the game. Here they are mounted to the mast and laid out for measuring with the spars.  They are attached using a "jack wire" system. Small brass cotter-puns are glued into holes every 6" down the aft side of the mast. Then you lay out the sail next to the mast and carefully cut small windows out of the luff of the sail at each cotter-pin. You leave a small amount of room both above and below the cotter pin for the sail to stretch as you apply downhaul. Then you run stainless steel wire through the mast crane and crimp it on. Now carefully route...

Today I used the laser cutter at work to cut sail numbers and insignia for my Sun Wind II wooden Vintage Marblehead sailboat. Turned out well! I used adhesive-backed insignia sailcloth . It even melted the edges a bit so they won't fray. My only concern is that the melting may have put a rough look onto the edges. The settings on the laser cutter were 100% speed and 1% power. I might try using even less power next time. The 1% didn't cut, or even scorch, the waxy paper underneath, but I'll do an experiment to see if .5% would more cleanly melt the edges. It's fun messing around in boats, and also laser cutters! I'll have to see how they look when I pull them all off. If they don't look good then I'll simply cut new ones by hand with a sharp hobby knife. Here is how the number 7 looked when I pulled off the surrounding material. The edges look slightly rough when you're right up at it, but when you're any more than just a few inches away, it...