I have made --maybe 10-15 covers. I have not made any in the last few years. I have a sailrite machine but I use my Consew 206-rb. I have made boom cover sail covers for Cape Dorys on the sailrite but never an Ensign full cover. The machine can do it, but the heavier commercial machine is easier.

I have a template somewhere. It may take me a bit to dig it up. But I am happy to share. My template is only the fore and aft panels. The boom cover portion is a rectangle. It needs to be the length the boom (11' 3"-- i think) and then the length from the center of the boom down will depend on how high you you keep your boom on the mast--generally about 55"-- dont forget a 1" seam allowance where you join material and a 4" hem allowance along the bottom edge (provides extra bulk for stability and to install fastners).

I have a source for sunbrella seconds, contact me and I will give you my source. I like to use lighter material than some folks. Depending --it may not last a long-- I will just make another. I have found even light material will last about 5 years provided you use uv thread. DO NOT scrimp on your thread or you cover will come apart quickly.

I use lighter material because it is easier to work with at the sewing machine and it is easier to handle and stow on the boat. The heaviest material I use is sunbrella marine 60" width. I use zippers in the front and back. Ensign Spars makes my clips. If you are handy, you can probably make your own out of pvc pipe. My husband just does not want to make them for me and I don't use a saw. You will need a tool to install the twist fastners. It takes about 10 yds of material to make a full cover. I use #10 jacket zippers. If you can get your material for $15 per yd, your zippers about $3 ea and fastners about $10 total-- So you can make a cover for less than $200. It is very rewarding to make your own cover. Good luck!

Fran Trapp

fran.trapp25@gmail.com

I have a Sailors' Tailor "Cockpit Cover / Sail Cover (COS)" made from their base material, the 14 oz. Polyester Army Duck. The $475 price has to be close to what you would pay for materials from Sailrite. It's a rugged cover that I believe will last the 10-plus years they claim. It's a very good deal for a custom cover. However, I can't say I'm completely happy with the fabric or the fit.

The fabric has a very heavy coating that feels like plastic. It's heavy and a little hard to fold because it sticks to itself rather than sliding when folding. Might not be important to some but I would prefer a material with a more fabric-like hand. It's claimed to be more durable than Sunbrella so for some the tradeoffs could be worth it. I was in a rush and the months-long lead time for Sunbrella wouldn't work for me at the time.

The fit is baggier than I expected and is downright awkward forward of the mast. The cover on my boat seems to want the forward end of the boom higher and the aft end lower. I've added an extension to the boom support on the backstay since the photo was taken but it is impossible to get the cover tight on my boat. Take a look at the pictures. Mine is the red hull (and it does hang better at the aft end now that I've extended the boom support). The picture with the blue hull is taken from Sailors' Tailor website.

Scott

Ensign 197, "Red"

Based on some quick searching I’m bringing back an old topic looking for fresh ideas. Bought a Sailrite sewing machine to reupholster my pontoon boat. I also need a new mooring cover for my Ensign. Has anyone made a mooring cover and have template plans they would be willing to share?

also considered buying one from SailorsTaylor if I can’t figure out how to make one. They offer many different fabrics and weights as options. Any recommendations on fabric choices either buying one from them or for making my own.

this is all new to me.