Company:
SALTY BUOY Marine Canvas Inc.

Project Details

Fabric 1

Sunbrella
Producer/Manufacturer: Glen Raven Custom Fabrics LLC
Primary Use: Main Fabric

Fabric 2

SolarFix PTFE Thread
Producer/Manufacturer: Quality Threads & Notions
Primary Use: Stitching


Design Name
Derek Newcombe

Design Company
SALTY BUOY Marine Canvas Inc.

Fabrication Name
Derek Newcombe

Fabrication Company
SALTY BUOY Marine Canvas Inc.

Installation Name
Derek Newcombe

Installation Company
SALTY BUOY Marine Canvas Inc.


Please describe the project specifications

We digitally templated, designed, fabricated, and installed a custom tensioned-membrane cockpit sun fly for Passat V, a historic 45-foot, 1951 German-built teak ketch based at the Vancouver Heritage Harbour. Delivering approximately 43 square feet (4 square meters) of functional shade across an overall footprint of 114 inches in centerline length by 146 inches in maximum beam width, the sun fly was fabricated from traditional Sunbrella marine-grade woven acrylic canvas in Linen, stitched with lifetime SolarFix PTFE thread, and constructed with integrated composite sail battens, polyester webbing, and 316 stainless steel carabiner and snap-hook hardware.

The client—a dedicated steward of this classic yacht—sought to replace an aging, mismatched, multi-piece canvas setup that was slow and cumbersome to handle. The goal was to deliver reliable helm and seating shade that honored the vessel’s heritage aesthetic while enabling rapid, single-handed deployment and strike before hoisting sails.

Blending modern shade-sail geometry with a 75-year-old classic ketch presented a complex physical puzzle. The dual-masted rig created a labyrinth of standing rigging stays, halyards, and mainsheet blocks. Rather than cluttering the deck with permanent stainless steel framing obstructions, we digitized the onboard spatial constraints in 3D to design a floating membrane that maintains aerodynamic boundary curves while navigating every obstacle. Suspended directly beneath the mizzen boom, the custom sun fly features engineered catenary boundary curves that tension the fabric and eliminate mid-panel sag without requiring a heavy frame. The shade cleanly bypasses the mizzen mast and stay rigging, projects outboard to the lifelines with captive battens, and fastens via quick-release snap hooks. When preparing to get underway, the entire assembly rolls around its battens into a single, compact roll for effortless stowing. The result delivered full helm UV protection, integrated soft-shackle loops underside for hanging lanterns, and a lightning-fast 90-second setup routine that maximizes sailing time.

A thoughtful design-for-fabrication strategy guided every step of the layered build. To achieve reinforced perimeter edges and corner junctions without external edge binding influencing the uniform membrane tension—or degrading under coastal UV—we devised an intricate inside-out assembly sequence. Every structural seam, hem, and corner junction is fully concealed within clean top-stitching, punctuated only by a single reinforced teardrop cutout tailored precisely around the aft mainsheet block.

Going from full anchor shade to sail-ready in about 90 seconds with a few satisfying clicks makes this one of the most rewarding and technically satisfying builds of our year.


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William Mainguy