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Bainbridge International Technical Manager Daryl Morgan walks Ali Wood through the full sail design and manufacturing process at Bainbridge's facility, using measurements taken the previous week from the PBO project boat, a Maxi 84 Maximus, as the working example.Watch

Modern sail design software builds a three-dimensional aerofoil shape and models clew movement, spreader clearance, and sheet lead — work that previously required a 1:50 scale drawing board or a full-size loft floor.1:57 The session covers the P and E rig dimensions, two-reef mainsail configuration, and the choice of a crosscut polyester mainsail paired with a radial-cut polyester-Vectran hybrid headsail.0:29 Bainbridge's Vectran cloth runs fibers in both warp and weft directions to reduce stretch and extend longevity.20:20

Roller-furling genoa sizing is explained in detail: a 130–135% LP is recommended as the practical maximum because it must perform from 5 to 25 knots, with efficiency dropping as it is rolled up.8:30 Storm jib deployment via a soft luff over a furled headsail is covered.13:22 The cruising chute versus spinnaker distinction — asymmetric versus symmetric leech length, pole requirement, and rigging complexity — is explained, and the PBO boat's chute will use 65 gsm MPEX 90 nylon.18:17 Sailcloth options run from crosscut Dacron (durable, shape-degrading over time) through cruising laminates with polyester, aramid, Dyneema, Spectra, or carbon scrims.27:14 Morgan argues sails are a boat's best long-term investment and advises buyers of used boats to inspect stitching, batten pockets, and general wear carefully.36:44

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