How to Repair Mylar Sails

Heavy wind loads might tear out grommets or blow Mylar sails completely.

Everybody says you can't repair Mylar sails and to a degree that's true. However, should your sail develop a small tear or a hole, you can make repairs that will get you home if you keep a few supplies on board for emergency sail repair. Like the doughnut spare in the trunk of your car, these repairs have limits; you should replace the sail or have the sail repaired professionally before using it again.

Things You'll Need

• Terrycloth towel
• Mylar sheeting
• Sharp jackknife or scissors

Instructions

1. Take the sail down and spread out the damaged area so that it's flat and uncreased. Wipe moisture and dirt away from the damaged area as much as possible with a terrycloth towel; this is critical to a serviceable repair.

2. Open the Mylar sail repair kit and pull out the Mylar sheeting. Cut strips no less than 2 inches wide from the sheeting, using a sharp jackknife or scissors to form a patch. If a large, irregularly shaped area is compromised, use the full width of the Mylar sheet.

3. Lay the Mylar strip on the damage on one side of the sail. Peel the backing from one edge of the strip and place the end at least 2 inches before the beginning of the damage.

4. Smooth the strip over the damage, peeling the backing from the Mylar as you do so. Turn the sail over and repeat the process, beginning with the cleaning of the damaged area, on the other side of the sail.

5. Remount the sail and proceed, gingerly, to the marina, the dock or shore.

Tips & Warnings

• When sailing with Mylar sails repaired with sail tape -- even Mylar sail tape -- you can't sail too close to the wind. This repair is only intended to get you home.

• Never sail past the limits of towing assistance unless you have a second set of serviceable sails.