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Paul and Sheryl Shard visit a sail loft in Makkum, Netherlands, to design the sail inventory for their new custom aluminum Orion 49.Watch The sail plan includes a double headsail rig featuring a 105% inner jib and a Code Zero-style Genoa for light air, both on furling gear.0:51 For high-latitude sailing, they specify a storm jib on a removable inner cutter stay equipped with an anti-torsion cable and a Profurl unit, allowing the entire stay to be removed for normal cruising.11:43 The mainsail design utilizes high-strength Dyneema cloth in an in-mast furling configuration.3:01 The sail designer balances the need for a flat sail profile to ensure smooth furling with enough camber for performance, incorporating reinforced reef points to handle heavy weather.5:42 The loft uses vacuum-table automated cutting for sail panels, which are then taped and stitched.10:15 The project aims to provide a versatile, easily handled rig for short-handed ocean passages and Arctic conditions.

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