Hardware & Reinforcement

Mainsail Hardware & Reinforcement

Hardware components and reinforcement specifications for mainsail construction.

Corner Hardware

Corner Reinforcement & Rings

Mainsails utilize appropriately sized rings and fittings based on boat size and application.

Cruising: Heavy-duty pressed rings or stainless steel structural rings.
Racing: Low-friction rings, webbing loops, or soft shackles for weight reduction.
Headboard: Aluminum or Carbon headboards to distribute halyard load (refer to specific headboard section).

Detailed Specifications: For a complete list of Ring Sizes, Materials (SS vs. Brass), and Types (Pressed vs. D-Rings), please refer to: Corner Fittings & Rings

Hardware Brands & Models

Eyes and Rings

Brand	Product Line	Sizes Available
Harken	Bullet Block	20-40mm
Ronstan	Series 55	16-50mm
Antal	Heavy Load	20-45mm
Wichard	Press Fit	18-35mm

Headboards

Brand	Model	Boat Size
Bainbridge	Standard	25-45ft
Selden	Composite	30-55ft
RWO	Carbon	Racing

Reinforcement Specifications

Spreader Patches

Round protective patches at spreader contact points to prevent chafe.

Shape	Material	Construction	Typical Size
Round	Taffeta + Dacron	Laminated or sewn overlay	150-300mm diameter

Material Details:

Taffeta: Woven polyester, tight weave for abrasion resistance
Dacron: Polyester sailcloth backing for structural support
Layers: 2-3 layers depending on expected chafe intensity

Placement: Positioned at spreader tip contact zone, both port and starboard sides

Thread and Tape

Thread Specifications

Sailmaking thread sizes and materials for different applications.

Polyester Thread (Standard)

Size	Tex Weight	Typical Application	Seam Strength
V69	Tex 70	Light panels, finishing work	Light-duty
V92	Tex 90	Standard panel seams, general construction	Medium-duty
V138	Tex 135	Heavy-duty seams, reinforcement areas	Heavy-duty

Properties:

Excellent UV resistance
High abrasion resistance
Standard for most sailmaking applications
Available in white and colors

PTFE Thread (UV Thread)

Material	Brand Name	UV Resistance	Application
PTFE	Tenara, Gore	Superior (virtually immune)	UV-exposed seams, leech, foot

Properties:

Lifetime UV resistance (does not degrade)
Higher cost than polyester
Slightly lower tensile strength than polyester
Available in limited colors (white, black, gray)
Used for: outdoor-exposed seams, furling sails, leech/foot reinforcement

Reinforcement Tape

Type	Application
Dacron webbing	Load paths, corners
Spectra tape	Racing, high-load
Adhesive film	Laminate bonding

Outhaul Systems

Clew Hardware Options

Clew attachment and outhaul systems for boom-mounted mainsails.

Type	Description	Components	Best For
SR Ring	Stainless steel spur ring	Pressed SS ring (#5-#6)	Standard cruising, traditional
Low Friction Ring	Soft Dyneema ring	Dyneema/Spectra ring	Racing, reduced weight
Webbing Loop	Heavy-duty webbing loop (no ring)	Polyester/Dyneema webbing	Ultra-light racing

Orientation Options:

Starboard (STBD) - Default configuration (most common)
Dual-Sided - Both port and starboard attachment points (offshore redundancy)

Outhaul Car Systems (Brand/Model Specific)

Brand	Model	Load Capacity	Mechanical Advantage	Application
Harken	150 Outhaul Kit	500 lbs	2:1, 4:1 options	25-40ft cruising
Ronstan	RF5125 Outhaul Car	800 lbs	3:1 standard	35-50ft performance
Antal	A2020 Outhaul System	600 lbs	2:1, 3:1	Racing 30-45ft
Selden	Boom Outhaul Kit	Variable	Complete package	Selden boom systems

Cunningham/Luff Tension

Cunningham Hardware Configuration

Luff tension control system installed above the tack.

Style	Description	Components	Mechanical Advantage	Best For
SR Ring	Stainless steel cringle	Pressed SS ring (20-30mm)	External tackle required	Standard cruising
Low Friction Ring	Soft Dyneema ring	Dyneema ring + webbing	External tackle required	Racing, weight savings
Webbing Loop	Heavy-duty webbing loop	Polyester webbing	External tackle required	Budget builds

Orientation:

Starboard (STBD) - Default configuration
Dual-Sided - Both port and starboard for offshore redundancy

Cunningham Control Systems

System Type	Mechanical Advantage	Description
Simple 2:1	2:1	Single block at tack, lead to deck
High-Ratio 3:1	3:1	Double block system, easier adjustment
Overhead	Variable	Line runs up luff, exits overhead (less deck clutter)

Leech Line System

Leech Line Specifications

Leech tension control for preventing flutter and curl.

Component	Specification
Line diameter	2-3mm
Exit point	~200mm from clew
Adjustment	External or internal

Leech Line Cleat Options

Type	Description	Installation	Best For
Overhead Exit	Line exits above clew, cleats internally	Through leech tape	Clean appearance, less snag
Velcro Cleat	Hook-and-loop fastener cleat	Adhesive or sewn	Quick adjustment, racing
CL 241	Clamcleat micro-cleat (model CL241)	Sewn into clew patch	Traditional, secure

Leech Line Mechanical Advantage

Configuration	Mechanical Advantage	Description
Direct	1:1	Simple line through leech, hand-adjusted
2:1 System	2:1	Small block at clew, easier tensioning
3:1 System	3:1	Double block setup, fine control (racing)

UV Protection Options

Acrylic UV Layer

Material: Acrylic fabric only (e.g., Sunbrella)

Properties:

Excellent UV resistance (5-7 year lifespan)
Solution-dyed for color fastness
Lightweight compared to Dacron alternatives
Available in many colors

Available Colors

Color Family	Common Options
Neutrals	White, Black, Gray, Taupe, Beige
Blues	Navy, Royal Blue, Pacific Blue, Aqua
Greens	Forest Green, Teal, Olive
Reds	Burgundy, Red, Terra Cotta
Yellows/Oranges	Sunflower Yellow, Orange
Custom	Special order colors available

UV Coverage by Furling System

In-Boom Furling Sails

Coverage Area	UV Protection
Leech	Full-length UV strip (sail rolls into boom, leech exposed)
Luff	None (luff protected inside mast track)
Foot	None (foot protected inside boom)

Typical Width: 300-500mm acrylic strip along entire leech

In-Mast Furling Sails

Coverage Area	UV Protection
Clew Patch	Small UV patch only (~300x300mm)
Leech	None (entire sail rolls into mast)
Luff	None (protected inside mast)
Foot	None (protected when furled)

Note: In-mast furling sails have minimal UV exposure when furled, requiring only a small clew protection patch.

Telltales and Windows

Telltale Specifications

Material: Standard nylon ribbon

Placement:

Leech telltales at each batten pocket
Standard configuration (no customization)

Purpose: Airflow visualization for trim optimization

Window Specifications

Material: PET film + grid fiber reinforcement

Availability:

Default: None (windows not included unless specified)
Optional: Can be specified by customer

Standard Sizes:

Small: 300x400mm
Medium: 400x600mm
Large: 600x800mm

Construction:

UV-stabilized PET (polyethylene terephthalate) film
Grid fiber reinforcement for tear resistance
Sewn or bonded into sail panel

Draft Stripes

Purpose: Horizontal reference stripes for visualizing sail shape and draft position.

Sail Size-Specific Widths

Sail Size (P measurement)	Stripe Width	Placement
<6m (20ft)	25mm	25%, 50%, 75% of luff
6-10m (20-33ft)	40mm	25%, 50%, 75% of luff
10-15m (33-50ft)	50mm	25%, 50%, 75% of luff
>15m (50ft+)	75mm	25%, 50%, 75% of luff

Available Colors

Color	Best Visibility	Common Use
Black	Light-colored sails	Most popular, high contrast
Red	White/cream sails	High visibility, racing
Blue	White sails	Good contrast
Green	White sails	Alternative to black
Yellow	Dark sails	High visibility on dark cloth
White	Dark sails	Maximum contrast on black/navy sails

Material: Sewn or printed onto sail fabric
Construction: UV-resistant polyester tape or printed directly

Taffeta Protection

Purpose & Benefits

Primary Function: Abrasion resistance and extended sail life

Benefits:

Protects sailcloth from chafe and abrasion
Extends sail lifespan (especially laminate sails)
Reduces surface wear from UV exposure
Reinforces high-wear areas
Provides additional support to laminate structure

Material Specifications

Property	Specification
Material	Woven polyester taffeta
Weight	30-60 g/m²
Weave	Tight, plain weave
UV Resistance	UV-stabilized polyester
Finish	Smooth, low-friction surface

Coverage Options

Full Sail Protection

Application	Coverage	Weight Impact	Cost Impact
Both Sides	Entire sail, port and starboard	+8-12%	+15-20%
Single Side	One side only (usually port)	+5-8%	+10-12%

Best For: Laminate sails, offshore cruising, high UV environments

Partial Protection

Area	Coverage	Purpose
Leech	Leech only, 200-400mm width	Flutter protection, batten pocket wear
Foot	Foot only, 200-400mm width	Boom contact, deck chafe
Panel Seams	High-load seams	Seam protection

Best For: Cruising sails, budget-conscious builds

Construction Methods

Laminated Taffeta

Feature	Specification
Method	Taffeta laminated between sailcloth layers
Application	Laminate sails (integrated during manufacturing)
Durability	Excellent (permanent bond)

Sewn Taffeta Overlay

Feature	Specification
Method	Taffeta sewn onto sail surface
Application	Retrofit, Dacron sails, partial protection
Durability	Good (serviceable)
Thread	V92 or V138 polyester

Maintenance

Component	Interval	Check For
Taffeta surface	Seasonal	Abrasion, tears, delamination
Seams (if sewn)	Annual	Thread wear, loose stitching

Replacement Interval:

Full taffeta (laminated): Sail lifetime
Partial taffeta (sewn): 5-8 years