A great step by step tutorial in a iwindsurf.com post
http://www.iwindsurf.com/forums/viewtopic.php?t=33806&start=0
I use the word tutorial loosely. Once you read all the steps, you'll be happy to pass the repair along to a pro and have it done right. I'll post later on some good temporary patch stuff when I'm in the mood.
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I've done a lot of sewing since I started making kites. You would need an industrial sewing machine - probably costing $1000 or more to do the sewing (even if all of the other steps weren't terribly difficult, which they appear to be.) Also - you need a really big work space to mount the sail on which most people don't even have the room for. The lady in Buxton will replace a panel (depending on its size) for $50-$100 or so. Just not worth even trying on your own.
BTW - aside from some really expensive racing sails, windsurf sails are probably the most complicated sails to repair around. It is telling that the sail repair shop on McEver road (I think it is still there) said they would never do windsurf sail repairs.
Fortunately - taping is such a good repair you don't need to have a panel replaced very often.
What happens in a black hole stays in a black hole.
Here is the el-cheapo version.
1. Buy this https://www.gorillatough.com/product/crystal-clear-gorilla-tape/
2. Apply this https://www.gorillatough.com/product/crystal-clear-gorilla-tape/ to both sides of tear
Alan
Not quite as el-cheapo:
Kevlar repair tape You can match your scrim lines.
Check ebay as it's often cheaper there but link not as long lasting.
Also, for luff sleeves, dacron sail repair tape. You can get it locally at West, too. Lighter weight versions for kites available, too.
For older monofilm, we used the heavy duty 3m packing tape (not generic cheap stuff). Gorilla tape is probably a bit stronger but for non-mission critical areas, this does fine.
Tip I learned from Foildood many moons ago: round off the corners (may .5cm radius) to inhibit dacron tape from peeling up.
Credit for the kevlar tape idea and how to use either Gorilla or Kevlar tape:
source: http://windsurfing.lepicture.com/windsurfing/tips-and-tricks/
I have to wonder how he managed to get a tear like that in that sail - not easy to do with x-ply. Mono tears much more easily but is easier to repair as well. I've had repairs made with simple 3M Packing tape last for year on monofilm sails.
What happens in a black hole stays in a black hole.
His pic of how it happened. Got dumped on by a wave. Nose of the board did the dirty deed.
He discussed his repair on a couple of forums
https://www.seabreeze.com.au/forums/Windsurfing/General/New-vid--how-to-repair-a-windsurfing-sail-with-x-ply?page=1
https://www.windsurf.co.uk/forums/topic/new-vid-how-to-repair-a-windsurfing-sail-with-x-ply/
Gorilla Tape