Make an Easy Duffel From Old Sails

Yesterday I posted about making an old bag out of a genoa sail that was torn up. My first attempt was a bit short and fat, so I wanted to try again. I also want to try to figure out a way to make the hole at the top more waterproof. Here is what I came up with, step by step.

The first thing I realized is that I could use the strip of sunbrella sun protection that are on most furling genoas. If I used that at one end I would have a double layer that I could use as an interior sleeve.

So first cut a rectangle of 32″ x 36″ with the 36″ running the length of the sunbrella.

You’ll see the sunbrella fabric has made a flap or double layer.

Fold the bag over so that the blue is on the INSIDE. We now have the bag inside-out. Sew up the long edge, but as you do so pull bag the blue edges and don’t sew those.

Then pull the flap/neck of the sailcloth back and sew up the edge of the blue. While we are at it, sew up the bottom.

While inside out, stick on 6 grommits.

Now push the blue inside, and pull out the white sailcloth. Sew on two bits of webbing, 1″ think with about 2″ overhang either end. This took me a bit of trial and error to get this step right. We are trying to get a roll over waterproof top.

While we have the bag inside out, sew up the bottom to make a square base as described in this Sunbrella video.

Now, when we turn the bag right side out, we can attach two clips to the webbing and this will make an interior closure.

As you can see from the top, you can roll up and close the bag to make it a little more waterproof. The rope holding it shut does not do a great job of perfectly closing it so there will always be a little hole.

Sew on a D ring and webbing across the base to hold the end of the rope.

Add cute helper, and you have a handy, weekend-trip -size, waterproof and robust bag!