Custom PolySails

Custom PolySails are one-off PolySails made to fill a customer’s need for a low-cost sail that looks good and performs well on a particular boat, dinghy, canoe, or kayak. With each sail that we build, we try to exceed that expectation with high quality material, workmanship, and sail performance for the lowest cost in the industry.

Customers can help us to fulfill our mission by doing their parts and understanding that most of the cost of a custom sail is in the time spent working on the sail. If a customer doesn’t come to us with a sail plan, then we must also add in the cost of research and/or design if the plan is not readily available in our boat and sail database, or with a quick Internet search. The same holds true for a sail that we must design from scratch to fit a nameless hull design or in adapting a sail to a boat that was not originally intended for sailing. We can usually design what is needed, but sometimes that process can be very time-consuming, and subtracts from the time we could be spending actually building sails.

Customers can help us speed up this process and keep our prices low by following these suggestions before they call or email:

  • Have the sail plan for your boat. The sail plan should have the edge dimensions for the sail(s). Four-sided sails also need a throat to clew (diagonal) dimension.
  • If you don’t have a sail plan, do an Internet search on your boat design to see if one is available. Use the boat design name, followed by a comma, then the word “sail.”
  • If no sail plan turns up on the Internet, taking a picture of your boat or copying one that you find on the Internet and sending the photo to us can be helpful.
  • One of the best databases for sail plan information is maintained by SailRite. Their filtered search can help you find the dimensions of the sail(s) for your boat.
  • It is also helpful in discussing a sail plan to know some basic terminology when speaking about sails. Mastering terms that identify sail corners, edges, area, and the center of effort (CE) can be helpful in providing your sail-maker with necessary information about your boat and sail. Jim Michalak’s essay on calculating a sail’s center of effort is instructive. (Read it here.)
  • Or, you can skip all this and just work through your needs with Dave at 317-385-3444 (cell) or polysail@polysail.com It’s part of what we do!

Alan Williams of Wrexham, England test flies his new PolySails aboard his recently constructed canoe yawl. Alan’s 90 year-old father acts as crew.

Christine Cochran of North Carolina, checks out the handling of her new Northwind Kayak with her 25 sq. ft. PolySail lug aboard. She
described it as “perfect” for her participation in the Water Tribe 300 mile Pamlico Sound event.

PRICING GUIDELINES FOR OUR STANDARD GROMMETED SAILS

Note: Shipping and handling costs are not included below.

3-SIDED SAIL SHAPE

3-sided includes:

Bermudan, Crab Claw, Jib, Genoa, Lateen, Leg O’ Mutton, Most Proa Sails

SAIL AREA WHITE SAIL WITH CHOICE OF TRIM COLORS COLORED SAIL WITH CHOICE OF TRIM COLORS REEFS, BATTENS, SLEEVES, WINDOWS, SLIDES, SLUGS, SHACKLES, TELLTALES, ETC.
3-sided Up to 37 sq. ft. or

Up to 3.5 m²

$90 $110 $30 ea. EXTRA COSTS PROVIDED IN QUOTE
3-sided

 

38—60 sq. ft. or

3.51—5.6 m²

$140 $160 $40 ea. EXTRA COSTS PROVIDED IN QUOTE
3-sided

 

61—75 sq. ft. or

6.61—7.0 m²

$160 $180 $40 ea. EXTRA COSTS PROVIDED IN QUOTE
3-sided

 

76—90 sq. ft. or

7.01- 8.4 m

$200 $230 $45 ea. EXTRA COSTS PROVIDED IN QUOTE
3-sided

 

90—120 sq. ft. or

8.41—11.1 m²

$250 $275 $50 ea. EXTRA COSTS PROVIDED IN QUOTE
3-sided

 

121—150 sq. ft. or

11.11—14.9 m²

$2.50 /sq. ft. $2.70 /sq. ft. EXTRA COSTS PROVIDED IN QUOTE
3-sided

 

Over 150 sq. ft. or

Over  14.91 m²

Call for Quote Call for Quote EXTRA COSTS PROVIDED IN QUOTE
4-SIDED SAIL SHAPE

4-sided Includes:

Gaff, Gunter,  Most Lug(s), Shoulder O’ Mutton, Solent, Sprit, Square

 

SAIL AREA

WHITE SAIL WITH CHOICE OF TRIM COLORS COLORED SAIL WITH

CHOICE OF TRIM COLORS

REEFS, BATTENS, SLEEVES, WINDOWS, SLIDES, SLUGS, SHACKLES, TELLTALES, ETC.
4-sided Up to 37 sq. ft. or

Up to 3.5 m²

$110 $130 $40 EXTRA COSTS PROVIDED IN QUOTE
4-sided 38—60 sq. ft. or

3.51—5.6 m²

$160 $180 $45 EXTRA COSTS PROVIDED IN QUOTE
4-sided 61—75 sq. ft. or

6.61—7.0 m²

$210 $230 $45 EXTRA COSTS PROVIDED IN QUOTE
4-sided 76—90 sq. ft. or

7.01- 8.4 m

$250 $275 $45 EXTRA COSTS PROVIDED IN QUOTE
4-sided 90—120 sq. ft. or

8.41—11.1 m²

$300 $325 $50 EXTRA COSTS PROVIDED IN QUOTE
4-sided 121—150 sq. ft. or

11.11—14.9 m²

$2.75/sq. ft. $2.95/sq. ft. EXTRA COSTS PROVIDED IN QUOTE
4-sided Over 150 sq. ft. or

Over  14.91 m²

Call for Quote Call for Quote EXTRA COSTS PROVIDED IN QUOTE
COMPLEX SAIL SHAPE

Complex Includes:

Arc, Chinese Lug, Kite, Spinnaker, Windsurfer, Prototypes, etc.

SAIL AREA ANY COMPLEX OR PROTOTYPE SAIL
Complex Any Sail Area Call for Quote

To see examples of our work or to post photos of your own PolySails or boat(s), visit our PolySail International Facebook Page.
Scroll down the timeline to find photos and albums of many recently completed sails.