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Ever wonder what happens to those massive sails after they’ve braved the seas for years? At Casco Totes, we turn them into stylish, durable bags. But before they become your next go-to carryall, those sails have a story. And it all starts with what they’re made of.
Sails aren’t your average fabric. They need to be strong enough to hold against wild ocean winds, UV rays, saltwater, and constant motion. So, the materials used in sailmaking are pretty hardcore. But over time, even the toughest sails reach retirement. That’s where we come in. We take those well-used, battle-tested sails and give them a second life.
To really appreciate what we do at Casco Totes, it helps to know what sails are made from in the first place.
Before modern materials came around, sailors relied on the natural stuff, fibers grown from the earth and woven into heavy-duty fabric.
Cotton sails became popular in the late 1800s. It was affordable, easy to sew, and performed well for casual sailing. But cotton soaks up water like a sponge and eventually stretches and rots. That’s why you won’t see it much anymore in new sails, but it’s a common material we see in older sail donations.
Long before cotton took over, flax and linen ruled the waves. These materials were super common on old European ships. They held up well and dried faster than cotton, but they were harder to get and more expensive to make.
Hemp was a go-to for ropes and sails because of its strength. It’s eco-friendly and durable, but like other natural fibers, it doesn’t handle moisture well. Still, some of the older sails we work with contain traces of hemp-based materials.
Fun fact: These older fabrics, with all their weathering, often have the most character. Perfect for one-of-a-kind bags.
Natural fibers had their run, but once synthetic materials hit the scene, everything changed.
If you’ve sailed on a boat in the last 50 years, chances are it had Dacron sails. Dacron is known for being tough, UV-resistant, and relatively inexpensive. It holds its shape better than cotton and is easy to repair. A big portion of the sails we recycle at Casco Totes are Dacron.
Nylon is the go-to for spinnakers, those big, colorful sails you see on racing boats. It’s lightweight and stretches just enough to handle gusty winds. But it doesn’t love the sun and can degrade if left exposed too long. We get a few nylon sails every now and then, and when we do, they usually add a splash of color to our collection.
Mylar sails are made from a thin plastic film and are mostly used in racing. They’re super lightweight and don’t stretch, which means great performance. But they’re not very durable over time and tend to delaminate. We don’t see many Mylar sails come through, but when we do, we get excited—there’s something cool about repurposing such a high-performance material.
Kevlar is insanely strong and super light, which makes it ideal for high-end racing sails. But it’s not great with UV exposure and tends to break down over time. We’ve repurposed some Kevlar sails before, but because of their fragility, we’re careful about how we use them.
These are ultra-high-molecular-weight polyethylene fibers (yes, that’s a mouthful) known for their insane strength and low stretch. They’re expensive and rare, but once in a while, we get our hands on a Spectra sail. And when we do, it becomes something special.
Carbon fiber sails are some of the most advanced materials in sailmaking. They’re stiff, light, and perfect for competitive racing. But they’re brittle and don’t handle flexing very well. Still, they look amazing and when we find one, we know we’re working with something pretty unique.
A lot of modern sails aren’t made from just one material, they’re made from layers.
Laminate sails often combine Mylar film with fibers like Kevlar, carbon, or Dacron to create a sail that holds its shape but lasts longer. These sails are designed for performance and durability but can be tricky to recycle due to the layering.
At Casco Totes, we break them down carefully. Sometimes we separate layers, and sometimes we repurpose them as is. Either way, these sails make bold, textured bags that really stand out.
Every good sail gets treated before it hits the water.
Sails live under the sun, so they’re often coated with UV-resistant finishes. These coatings extend the life of the fabric and help it hold color.
Moisture is inevitable, but some treatments help repel water and prevent mildew. These features are super handy, especially for repurposing. A well-treated sail means less cleanup on our end and a cleaner canvas to work with.
Laminate sails often use heat and resin to fuse layers. This adds stiffness and strength, but can also make the sail harder to stitch through. Still, we love the challenge.
Here’s a quick overview of the most common types of sail fabrics and their key traits:
| Material | Type | Strength | UV Resistance | Common Use |
|---|---|---|---|---|
| Cotton | Natural | Medium | Low | Historic sails |
| Dacron | Synthetic | High | High | Cruising, casual use |
| Nylon | Synthetic | Medium | Low | Spinnakers |
| Mylar | Synthetic Film | Low | Medium | Racing sails |
| Kevlar | Aramid | Very High | Low | High-performance racing |
| Dyneema/Spectra | Synthetic | Very High | High | Racing, Industrial use |
| Carbon Fiber | Composite | High | Medium | Elite racing sails |
Matching Sailcloth to the Job
Not all sails are made for the same conditions. Here’s how sail materials change depending on where and how they’re used.
We see it all at Casco Totes, and we treat each sail differently based on what it was built for.
Every sail tells a story. Whether it crossed the Atlantic or stayed local, it holds character; and we try to keep that intact.
When we choose sails for our bags, we look at three things:
Some bags come with old stitching lines, faded sail numbers, or reinforced patches. We don’t hide these details, we highlight them. They make your bag feel like a piece of living history.
We started in 2008 during the recession, just trying to keep things afloat. What began as a side project quickly became something bigger. We realized people loved the idea of turning old sails into something useful and beautiful.
We try to recycle up to 90% of each sail. That includes everything from the main body to little scraps we turn into smaller accessories. The goal is simple: keep sails out of landfills and turn them into bags you’ll actually want to carry.
Each bag is handcrafted. No two are the same. When you carry a Casco Tote, you're carrying a piece of real sailing history.
Most of our bags are made from Dacron sails because they’re durable and easy to work with. But we use everything from cotton to laminate, depending on what’s available.
They’re highly water-resistant, especially if they come from treated sails. However, since many bags are stitched rather than welded, we don’t call them 100% waterproof.
Absolutely. That’s part of the charm. We embrace the imperfections like scuffs, stitch marks, and old sail numbers. It’s what makes each bag one-of-a-kind.
Yes! We’re always on the lookout for usable sails. Just give us a call at (207) 865-2100 and we’ll walk you through the process.
Sail materials aren’t just fabric, they’re feats of engineering built to survive wind, water, and time. At Casco Totes, we’re proud to give them a second life. Every tote we make is stitched with purpose, history, and care.
If you’ve ever wondered where your bag came from, now you know. And if you’ve got an old sail lying around, you know who to call.
Interested in owning a piece of recycled sailing history? Check out our latest designs and learn more at Casco Totes or call us at (207) 865-2100.
PO Box 126
South Freeport, ME 04078
