Oh for Blue Sails... Double Layered Dacron?

[davecalvert]

I believe Challenge Sailcloth has some dk. blue 6 oz. dacron cloth available.
This, with a wide 2 ply head, leech and clew, (50% to 60%) may work well.
We have also used water based acrillic paint to paint stripes for charter cat mainsails. This held up well. We also build an offshore load path sail in colors. This would have a taffeta on one side.
Dave from Calvert Sails

[rhumbunctious]

In further considering the two-ply approach, I've been researching the two-ply wrap around sails originally used on Freedom yachts. While not identical to two layers fully sewn together, there are useful similarities.

I found it interesting that I was unable to find any discussion about either chafe or mildew being a problem, and the key reasons for moving later to single ply with a track was to allow for battons and because the wrap around luff had a tendency to creep around the mast and spoil the sail shape.

I also found reference to a few offshore racing yachts of yore which had fully two-ply sails for strength, in the early days of dacron.

So I'm still not ruling out the two ply approach. Will be talking more with sailmakers to get additional expert input on the options.