REVISED SOW COPY UpperTopsail Encl 1.doc

REVISED COPY 7/21/20

STATEMENT OF WORK

USCGC EAGLE (WIX 327) NEW SAIL CONSTRUCTION CONTRACT

UPPER TOPSAIL – 04/25/2020

1.0

CONSTRUCTION SPECIFICATIONS:

1.1 General Specifications:

1.1.1 The selected contractor will construct the sails listed and described in the following paragraphs. Drawings are included for reference. Specifications describe the minimum acceptable standards. The Contracting Officer’s Technical Representative (COTR) is BMC Leland Currier and the alternate is BOSN Spencer Greer, USCGC EAGLE (WIX 327). Contractors may deviate from the written specifications to take advantage of new technologies or enhanced construction processes. However, any deviations from these specifications must be approved in writing by the KO before implementation.

1.1.2 The contractor will provide the COTR with a set of construction patterns or drawings for approval before starting construction. These drawings or patterns must indicate any deviations from the minimum standard. Within three business days of receiving the proposed patterns, the COTR or KO will either approve the patterns in writing or submit a discrepancy list to the contractor.

1.2.

Construct one vertically cut Upper Square Sail of about 1102 square feet with these approximate dimensions:

Cloth Weight - 16 ounce, white, warp oriented, balanced construction “North Oceanus” Dacron sail cloth with full ultra violet (UV) light protection.

Panel Width – Construct the sail using 20” wide (finished width) panels of sail cloth.

Maximum Head Length – 56.58 feet

Maximum Leech Length – 18.50 feet

Maximum Foot Length – 65.67 feet

LC (Head) – 9 inches Leech Hollow – 3 inches Foot Hollow – 31 inches Rings:

“Head Earrings” – Two (one for each corner of the head) contractor furnished 3.5 inch (ID) 316 stainless steel ring made of ¾” stock spliced to the external, hand stitched bolt rope.

“Clew Iron” – Two (one for each corner of the foot) contractor furnished 3.5 inch (ID) 316 stainless steel ring made of ¾” stock spliced to the external, hand stitched bolt rope. Samples for taking measurements are available aboard EAGLE.

1.3.

Bolt Rope: Construct all sails within this scope of work with a three strand, white, spun Dacron, external bolt rope hand sewn to each sail’s full perimeter. The Bolt Rope will form the structural frame work of the edge of the sail. Ensure each strand of the bolt rope is stitched to the sail cloth.

1.3.1. Hand sew a 1” diameter external boltrope along both leeches and the foot.

1.3.2. Hand sew a ¾” inch diameter external boltrope along the head.

1.3.3. Eye splice eight appropriately sized stainless steel thimbles, one spliced into each bitter end of the bolt rope, at each of the sail’s four corners. Splice these “bolt rope” bitter ends into the head and tack earrings and the clew iron.

1.3.3 Hand cross stitch the hand sewn bolt rope at all corners, eyelets, splices, rings, twine ends and seam ends.

1.3.4 Sew the external, hand sewn bolt rope to the sail cloth on the port side using “a single plied yarn of 5/8” dacron line” or sail twine. If used, the sail twine must meet or exceed the diameter and breaking strength of “a single plied yarn of 5/8” Dacron line.”

1.3.5 Using chrome leather cover the bolt rope as required for chafe protection.

1.4 Thread: Construct all sails within this scope of work using UV resistant, white #277 polyester threads for all stitching, other than the hand sewn, external bolt rope.

1.5 Seams: Construct all sails within this scope of work with seam widths of at least 1 ½ inches but not more than two inches in width. Sew the seams with either two rows of three step zigzag stitching or three rows of triple zigzag stitching. Sail panel seams must be hot knifed of flag seamed to prevent fraying of selvage edges.

1.5.1 Ensure no stitching “steps” over the edge of the seam material.

1.5.2 Sew the linings, tablings, and turns along the perimeters of the sails with two rows of straight stitching made with #346 machine thread.

1.5.2.1 In some cases, because of restricted space the sail maker may opt to use only one row of #277 machine thread straight stitching along a sail’s perimeter or in the linings, tablings and turns. In these cases, refer the matter to the Coast Guard Inspector who will decide if one row is sufficient or if two rows of straight stitching are required on a case by case basis.

1.6 Ultraviolet Protection Head Panel: Install a 36” protective head panel made of eight ounce, white, Acrylic cover cloth on the after side of the sail and along the head. Acrylic is a UV resistant synthetic woven fabric.

1.7 Pressed rings described in the part may be substituted with Inox rings of similar style

Construction when authorized by the COTR.

1.7.1 Head Grommets: Install 25mm black nylon washer with stainless steel liner Rutgerson pressed rings along the sail’s head. Space the Rutgerson rings evenly along the head’s length at the intervals not exceeding 20 inches.

1.7.2 Leech Grommets: Install one 35mm black nylon washer with stainless steel liner Rutgerson pressed ring on each leech. Posistion each of these grommets such that when the leech line is hauled in fully and the sail’s clew is hauled up tight there is equal pull in both directions (leech to clew and leech to earring).

1.7.3 Foot Grommets: Install four 35mm black nylon washer with stainless steel liner Rutgerson pressed rings along each square sail’s foot below each of the “buntline bulls eyes” described in paragraph 1.8.

1.8 “Buntline Bulls eyes”

1.8.1 Construct the grommets for the bull’s eye lizard from a single strand of 5/8” Dacron line laid up in a tight grommet. Hand sew the grommets into the sail in the specified positions. For the “bulls eye lizard” use a 2” outside diameter black nylon thimble. The bull’s eye lizard is made from ¾” Dacron line turned around the thimble and seized. Pass the lizard tails through the buntline grommet and unlay them. A Mathew Walker knot, acting as a stopper, is then tied on the aft side of the sail. Then hand sew the two braids to the sail.

1.8.2 Install four of these “buntline bulls’ eyes.” To position the “buntline bulls eye’s” measure in one third of the head’s length from each leech toward the center of the sail. At each of these points install two “buntline” bulls eyes spaced equally along the vertical line between the head and foot of the sail.

1.8.3 Along the “vertical line” formed by the “buntline bull’s eyes” install a “buntline cloth” on the front of the sail running from the head to the foot of the sail. This “buntline cloth” is equal to the width of one panel of sail cloth. Make it of 7-10 ounce, white “North Oceanus” ships sail cloth. If 7-10 ounce Oceanus is not the optimal weight for a “buntline cloth” the contractor may recommend a different weight of cloth. The COTR must approve the change before implementation.

1.9 “Reinforcing patches and chafing gear”

1.9.1 Reinforce and protect from chafe all corners, Rutgeron pressed rings, “buntline bulls eyes,” “earrings” and clew irons as required using the following guidelines.

1.9.2 Patches – Install reinforcing patches as needed using the following guidelines

1.9.2.1 Ensure the cloth direction in the patches is oriented in the same direction as that of the surrounds sail. All patches must be hemmed.

1.9.2.2 Install diamond shaped buntline bulls eye reinforcing patches over sail panel and buntline cloth. These patches should be constructed of sailcloth of similar weight to the buntline cloth.

1.9.2.3 Proportion the patch length along the leeches and foot of the sail such that the effective construction forms one continuous patch from the earrings to the clew irons.

1.9.2.4 Install at least five patch layers at the clews and head corners. Preferably the proportions will be such that six layers of sailcloth run the full length of each leech and nine layers of sailcloth are sewn in at the earring and clew corners.

1.9.2.5 Proportion the separation between the perimeters of the patches to gradually transfer the strain from the point of maximum stress out to the unreinforced cloth.

1.9.2.6 Ensure corner patches distribute the strain in the correct direction.

1.9.3 Chafing gear: At all head, leech, and foot Rutgerson pressed rings install chrome leather chafing gear to protect the sail cloth. Protect other chafe points on the boltrope, along the head, foot, and leeches, and all other chafe points as necessary.

1.10 “Head Earrings” and clew irons:

1.10.1 At the head corners, splice two contractor furnished 3.5” inside diameter (ID) by ¾” 316 stainless steel earrings (one at each head corner) to the external hand sewn bolt-rope.

1.10.2 At the clews splice two (one for each corner of the foot) contractor furnished 3.5 inch (ID) 316 stainless steel ring made of ¾” stock spliced to the external, hand stitched bolt rope.

1.11 Belly Band:

1.11.1 Install a reinforcing “belly band” on this ail which divides it into smaller units. Construct the “belly band” of five inch wide, 15 ounce, “North Oceanus” ships sailcloth rubbed under on the top and bottom. Sew across the sail’s width from leech to leech. Place the band such that it is centered between the head and foot at the bunt. Run it parallel to the head’s full length out to each leech.

1.12 Waster Panel

1.12.1 Sew a 36” wide panel of eight once, white, acrylic waster panel on the after side of the sail. Center this “waster panel” along the sail’s centerline running from the head to the foot. This panel will ride along the yard’s track and prevent the grease on the track from soiling the main body of the sail. Rub both sides of the top and bottom of the “waster panel” under. This panel is intended for replacement as often as annually.