American Custom Sails

Fresh One Design Viper 640 spinnaker sent out the join the fleet in Hampton, VA. Some small custom work with the star inlays on the luff. Apart from giving the sail its full character the stars are placed along the luff vertical to give feedback to the trimmer for optimal shape. Can’t wait to get some pictures of this spin out on the bay!
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Fibermax 44 ripstop
Integral dyneema clew lead
Pressed ring head/tack
Dousing patches
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C&C 110 Heavy 95% (Frankensail)
-Full roach design
-Vertical furling RBS battens
-integral soft shackle clew
-AWS 18kts +

A years worth of sailcloth seconds went into this sail giving it the unique tricolor panel patterning, and of course the name from the crew. Along with a custom inhauler setup, the sail performs beautifully in heavy breeze, keeping the boat balanced with just the right amount of power.

C&C 110 Cruising 130%
Palma-Tec 18
AWS-Bulletproof

The first sail I built myself, far from perfect. Many lessons learned about initial sail design, mainly what you can’t do! Last fall this Genoa had a leech recut and reshape and is back on as the primary cruising headsail.

C&C 110 Superlight 155% (1-Schwifty-5)
-SSGP 1.8/2.7oz
-integral Soft Shackle clew
-AWS 0-12kts

The goal was a no penalty code-like sail for the dying breeze on weeknight JAM races. The solution, the superlight. This sail weighs in just under 1/3 the weight of our 130% Genoa, sub 25lbs bag weight!

Since today is 1/10 there’s no better boat to showcase than the lofts test boat, C&C 110 OPTIONS. This boat has about every evolution in my sailmaking journey documented. From the first sail I ever designed and built fully myself, to now dialing in the details on our new additions.

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INVENTORY

Superlight 154%
Cruising 130%
Heavy battened 95%
A1.5
A2

Cruise Main
Race Main

Turbo Hobie 21SE square top racing main and jib

Square Top Main
Pxb 10/15 split
RBS tapered battens and rocket tensioners
Integral dyneema tack loop

110% jib
Code Zero GP/Pxb 05
Aramid Zipper luff
UV furler sock
UV Main Roll Bag

Hobie 33 Turbo superlight #1 jib

Built for dying Wednesday night breeze and short course racing this jib is the boats real upwind power. The code zero luff panels give the sail the flexibility to change gears quickly, while maintaining a strong leech profile and clean slot to the main.

Full roach, phrf max design
Tyraply 4.2oz leech
Super Series GP 06/09 luff and foot
Adjustable Carbon RBS battens
Reinforced headstay wrap
Clip-on soft hanks

F24 Masthead A1.5

This full racing spin challenged us with a large, multi piece inlay of a stormtrooper helmet. Using Airx ripstop makes it a breeze, and makes it hold up in a breeze, thanks to no sew seam construction.

AirX 500N .37oz
PHRF max design
2:1 dyneema luffline
Custom graphic inlay
Racing launch bag

C&C 110 120% performance cruise Genoa

This sail went out to our friends on the west coast for some ocean sailing. Pro Radial’s strength and UVi coating was a must for the customer to keep the sail pushing in heavily blows and extended sun exposure.

Pro-Radial 7.6oz
Sun-tec ultralight UV cover
Padded foam luff
Easily visible reefing marks

Full tanbark inventory for this flicka 20. The mainsail uses a cross radial panel layout for balanced shape in a wider wind range and added aesthetics.

To keep these beauties protected we also built new deck bags, mainsail cover, and tiller cover.

Stay tuned for the final addition to the quiver, a custom inlayed A2!

Catalina 34 tall rig performance cruise mainsail

This sail was maximized for solo challenges and distance cruising on the Great Lakes. Built from Pro-Radial this sail is built to withstand whatever the skipper throws at it. Its debut showing on the 2024 Lake Erie Interclub Cruise resulted in a first in class finish!

Pro-Radial 7.6/9.4 split
4 Full RBS adjustable tapered battens
Dutchmen flaking system
Higher reef placement for solo sailing.