How to Make El Toro Sails

The El Toro is a one-design class of sailing dinghy. It is a popular craft among those who wish to teach their children to sail, due to its stability. In addition, the El Toro is a popular racing dinghy, with many fleets devoted to its design throughout the United States. The El Toro craft is designed to use only a mainsail. Follow the instructions provided by the El Toro Racing Association, if you are making a sail to conform to racing standards. These detailed instructions include the nominal foot, leech and luff for the sail.

Things You'll Need

  • 1 piece of plastic tarp, 9 by 12 feet
  • Measuring tape or yardstick
  • Pencil
  • Scissors or other cutting device
  • Sewing machine or #16 triangular-shank needle
  • Polyester fiber thread (machine sewing)
  • Waxed polyester sail twine (hand sewing)
  • Bobbins for sewing machine
  • Sail maker’s palm (hand sewing)
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Instructions

  1. Measuring the Sail Dimensions

    • 1

      Measure and mark the foot (width) of the sail. Your sail should measure precisely 7 feet wide.

    • 2

      Measure and mark the luff (height) of the sail. Your sail should be 10 feet, 11 inches tall.

    • 3

      Measure the leech (diagonal length) of the sail. Lightly mark this measurement as a broken line, using a pencil. The leech should measure no more than 12 feet, 2 inches long. Mark the sail along the leech, dividing it into three even sections.

    • 4

      Measure and mark the roach (convex curve) of the front edge of the sail. Your sail should measure no more than 42 inches at the upper girth, the point at which the top batten pocket will be set. Your sail should measure no more than 72 inches at the lower point of the girth. Mark this convex edge with straight lines, connecting the upper girth with the top point of the luff. Connect the upper and lower girth. Connect the lower girth and the end of the foot opposite the base of the luff. Cut along all solid lines.

    Add the Batten Pockets

    • 5

      Measure and mark the areas where the batten pockets will be placed. The upper batten pocket should be no longer than 27 inches and 2 inches wide. It should be placed at the edge of the upper girth and should extend at a right angle across the leech. The lower batten pocket should measure no longer than 31 inches and 2 inches wide. It should be placed at the edge of the lower girth and should extend at a right angle across the leech.

    • 6

      Measure and cut the material for the batten pockets. Leaving a seam allowance of 1/2 inch, prepare a piece of material 27 1/2-inches long and 3 inches wide. Leaving the same kind of seam allowance, prepare a piece of material 31 1/2 inches long and 3 inches wide.

    • 7

      Attach the batten pockets. Cut the corners of each piece of material at a diagonal, about 1/2 inch from the tip. Fold seam allowances under and sew in place. Use a whip stitch, four to five stitches to the inch, if sewing by hand.