Sent my hand threw my sail during a crash today at the end of a sick powered up session on my foil and this 2001 aerotech charge 3.5. It was 2C out. The way it broke was like glass, not your usual tear so I assume the cold played a part in it. 20 y/o monofilm doesn't help
But this is a awesome sail so would like to keep her going if I can but she definitely doesn't owe my anything.
Worth patching up with goralla tape
I already have a full roll of clear gorilla in this sail before this hole, the tape works well but how well...

Can you get sticky-back sail repair film? You could probably patch it and make it stronger than new.

Bin. Yes you could patch it but you've broken one of the shape seams. They never go back the same way.

A decent sail maker can patch that and keep the seam shape in but it would probably cost the same as a second hand sail to repair and I'd say that the rest of the mono film is probably on its way out too.

Sails have improved massively in the past few years and theres some cheap second hand ones about.

Design of that sail looks pretty old. My guess is that the other panels may be on their way out.

The other panels are definitely on there way out. Medge, I agree it would definitely cost more then the sails worth to professionally repair it. Will try my luck with Gorilla clear tape and keep my eye out for a used one. I haven't seen too many in this size though.
I would definitely try a new aerotech charge after having this one, it's such a awesome sail; tons of power and goes super neutral for transitions. I imagine all new wave sails do that these days. Best of all this sail works well with a 400cm mast.

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FormulaNova said..
Can you get sticky-back sail repair film? You could probably patch it and make it stronger than new.

Haven't heard of that I do have some old sail repair tape with x-ply but it isn't nearly as sticky or strong as gorilla tape.

We had a set of four sails that we loved, and their end started a bit like what you describe. The first to break was in a crash, and we had the panel replaced. But within a the next couple of months, the others started to break, too, at the slightest provocation (like carrying a sail on the head). This happened in late fall / early winter, and cold weather probably played a role, but the primary reason was age and a lot of use. Taping some of the earlier breaks would only last a couple of sessions, then another panel would go.
The same story repeated itself a few years later with another sail. It was just ~ 4-5 years old, but after around 100 session on it, it started falling apart. The first panel was in a crash so I got it replaced, but very soon afterwards, top panels started breaking just from the sail hitting the water. The sail repair lady did not want to touch it, and I gave up taping when 4 different panels had tears in them.
But if you're lucky, your sail is different.

Why Not get a quote on the repair. If it's lots don't do it if it ok price do it. The sail may last another session or the whole season.

Bin it! If its that old the next rippy tear tear could leave you swimming a long way home.

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olskool said..
Bin it! If its that old the next rippy tear tear could leave you swimming a long way home.

I will add that the sail was some how sailable with the huge hole. Wasn't far from shore but got foiling just like being on a 3.3m
The water here is just above freezing so you don't want to be swimming much.

Could be a new venting system, where if you get overpowered you simply kick out the foot panel and reduce the sail area.

Pushing it there! My main panel is nearly 100% covered with tape (2017) but max tear size is a few inches (20cm). However nothing in the downhaul tension area, that part needs stitching support.

Gorilla tape may hold for a few sessions until tension starts sliding it off creating a a bulge there.

Is it worth half a roll? Your call!

Clear Gorilla tape, first do one side vertically across the whole hole (not just on crack), then tape onto the other-side, so two layers thick of tape and one layer of original x-ply in the end, $7 a roll, worth a try.

2001 ? - maybe time to replace

Or send to Aerotech at their Sandypoint location in S. Daytona Beach, not sure what shipping costs would be, I have driven their to get a sail fixed under warranty, took two days, great place to vacation at Wekiva Springs State Park for kayaking, or a great spot to windsurf on the intercoastal. But that is a big panel, not sure what it would cost.

So I gave it a try repairing with black gorilla tape. Super strong stuff almost bonds to the monofilm like glue. The hard part with this repair is getting the seams to line up right. Since there's so many tears going in different directions. I used green painter's tape tacked the one side on, taped every few inches until it lined up half decent. Then gorilla taped the other side. Removing the green tape and doing the same. Was quite a bit of tape but had it laying around and I kinda like the new graphics. Will see how it holds up. A new sail will likely be on it's way for next year, love these Aerotech charge sails. This was my first one and I'm definitely hooked now.

Should hold for at least a few sessions!
Do report back after, I wonder if the sun may soften the glue especially using black tape.
It's nice they have a clear version too, that's what I use with no issues: