Bosun s Chair Kit. Kit # * *1 MATERIALS LIST:

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1 103824* *1 Bosun s Chair Kit Bosun s Chair Kit Kit # The Sailrite Bosun s Chair Kit makes a padded bosun s chair using Sunbrella acrylic fabric and closed cell foam. The design features a side pocket for storage, tool loops, and a D-Ring that could be used to direct the chair from the deck. The chair is extremely safe, very comfortable, and flexible so it fits snugly against the hips when hoisted. The dimensions provided in these instructions will build a chair for persons under 250 lb. Adjust the dimensions as needed to construct a smaller or larger chair. We recommend making a test chair to determine proper dimensions before building a chair capable of hoisting heavier individuals. Connect the completed bosun s chair to a halyard and use a winch to hoist up the mast. Use with a Trammel Safety Harness connected to a separate halyard as a secondary safety line. This kit requires the use of a sewing machine. Set your machine to straight stitch with the longest possible stitch length. MATERIALS LIST: KIT # Sunbrella Fabric 2 yds. 3/4" Sunbrella Binding 4 ft. 2" Nylon Webbing 14 ft. 1" Nylon Webbing 2 ft. 1 oz. V-69 Thread 1 5/8" Velcro Loop 1 ft. 5/8" Velcro Hook 1 ft. #3 D-Ring (2-3/8") 3 1/2" 56" Closed Cell Foam 1 ft. Instructions 1

2 Bosun s Chair Kit Cut Strap 1. Primary Support Strap 1. Lay out the 2" webbing. 2. Cut the webbing to an 80 inch length using a hotknife if possible to seal the ends and keep them from raveling. 6" 3" 1.2 Attach D-Ring to Webbing End 1. Measure and mark a line 6 inches from one end (A). 2. Fold the end to the line to create a 3 inch fold (B). 3. Slide the straight side of a #3 stainless D-ring in the fold. 4. Sew the fold/loop down with a Box-X stitch (C). Sew a box first and then proceed to sew the diagonals, reinforcing the top and bottom stitch lines. 5. Repeat these steps to attach a D-ring to the opposite webbing end.

3 Bosun s Chair Kit 3 2. Fabric Panels 70" 4" 13" 16" 2.1 Pattern Seat 1. Lay out the fabric and mark 2 pieces using the pattern (A) provided. 2. Cut out the patterned panels from the fabric using a hotknife or soldering iron with a flat blade if available. Scissors can be used since all edges will eventually be folded under or hemmed. 3. Label the side and side of each panel to aid in construction. 2.2 Hem Short Ends 1. Measure and mark a line on the side 1 inch inside the 4" long ends on both panels. Fold the edge to the marked line. 2. Sew a row of straight stitches along the folded edge of the hem (B). 2.3 Hem Slanted Ends 1. Measure and mark a line on the side 1 inch inside the slanted edges of both panels and fold to the marked line. 2. Sew a row of straight stitches along the folded edge of the hem (C). NOTE: Do not hem the 70 inch side or the 16 inch side on either panel during this step.

4 Bosun s Chair Kit 4 3. Attach Primary Support Strap 1/2" 3.1 Position Support Strap 1. Lay one fabric panel side up (hems face up). 2. Center the support strap across the panel and position 1/2 inch inside the long 70 inch edge (A). 3.2 Attach Strap to Panel 1. Sew a single row of straight stitches 1/2 inch inside both long edges of the support strap (B). 9" 9" 3.3 Mark Measurements 1. Flip the panel over to the side. 2. Along the bottom edge, find the center of the panel and make a mark. (C). Mark 1 inch on each side of the center. 3. Draw a dotted line from each end of the 16 inch side down to the bottom edge, perpendicular to the long edge (D). 4. On each side of the panel, from line D measure and mark 9 inches out. Mark 1 inch on each side of this mark (E). 5. On each line D measure and mark 1 inch down from the top edge (F).

5 Bosun s Chair Kit 5 4. Leg Straps 4.1 Cut Straps 1. Lay out the remaining 2" webbing. 2" 2. Cut 2 lengths of webbing each 22 inches long using a hotknife. 4.2 Position Straps 1. Lay the 2 straps on top of one another. 2. Place the straps in the center of the panel at a 90 angle to the primary support strap. The leg straps should protrude 2 inches beyond the long edge (A). 4.3 Sew Straps 1. Lay the blank fabric panel directly on top of the panel with the attached webbing assembly with the sides of the panels facing each other (B). 2. Flip the assembly over so the primary support strap is on top (C). 3. Secure leg straps with a row of straight stitches (through all layers) about 2 inches long right along the edge of the primary support strap (D). Note: Use a zipper foot on the sewing machine to sew right next to the webbing edge.

6 Bosun s Chair Kit 6 2" 4.4 Create Loops 1. Open up the panels. 2. Slide both legs straps through a D-ring (D). 3. Transfer the 9 inch marks from Step 3.3 to the opposite panel (so both panels have the marks) (E). 4. Position the loose end of one leg strap over the nearest 9 inch mark with 2 inches of the strap past the edge on the panel without the webbing assembly. Sew a short row of straight stitches close to the edge to tack the leg strap in place (F). 5. Repeat to secure the opposite leg strap across the other 9 inch mark.

7 Bosun s Chair Kit 7 5. Attach Fabric Panels 5.1 Join Panels 1. With the sides of the panels facing each other, sew a row of straight stitches through all layers along the long 70 inch edge as close to the primary support strap as possible (A). Start in the center of the panels and sew toward one side, then start at the opposite end and sew toward the center. Avoid sewing over the loose leg straps. 5.2 Sew Webbing Flaps 1. Open up the panels and lay them flat with the side facing up. Sew the 2" webbing flap back over top the primary support strap using a Box-X stitch (B). 2. Repeat to secure all 3 webbing flaps against the primary support strap.

8 Bosun s Chair Kit 8 6. Seat Bottom Pocket 6.1 Join Panels 1. Fold the panels so the sides are facing out and the sides are facing each other. 2. Starting 1 inch in from the 16 inch edge, sew a row of straight stitches straight back following the guide line (A). Repeat to sew a parallel line on the opposite side of the chair. Avoid sewing over the leg straps. 7.1 Cut Strap 7. Back Support Strap 1. Lay out the remaining 2" webbbing. 2. Cut a length of webbing 38 inches long using a hotknife. This strap will be used as the back support strap. 7.2 Attach Strap 1. Lay the strap so that it lays from one side of the chair around to the other (opposite side than the leg straps). 2. Take one end of the webbing and place it between the fabric panels directly on top of the sewn webbing from Step 5.2. Make sure the webbing is parallel to the seat stitches. Close the fabric panel. 3. Sew a Box-X stitch directly over top the existing Box-X stitch and continue a row of straight stitches along both edges of the back support strap and stop 1 inch from the edge (A). Reverse (bar tack) over the stitch ends to lock in place. 4. Make sure the strap will lay flat and then repeat these steps to attach the opposite end of the back support strap over the Box-X on the opposite side of the chair (B). 5. Trial fit the chair for size and make any necessary adjustments.

9 Bosun s Chair Kit Cut & Insert Foam 8. Foam 1. Cut a piece of closed-cell foam to an 11-1/4 inch length by 15 inch width. 2. Slide the foam into the seat bottom pocket. 1/2" 8.2 Sew Seat Closed 1. Fold both raw edges inside 1/2 inch and either baste or pin in place if necessary (A). 2. Sew along the edge with a row of straight stitches to close the seat bottom pocket (B). 9. Chair Pocket (Optional) 15" 5" 10" 7" 1 1/2" 20" 9.1 Prepare Pocket 1. Lay out the remaining fabric and pattern a pocket using the dimensions provided (A). 2. Cut out the patterned pocket from the fabric using a hotknife if possible. Scissors can be used since all edges will eventually be folded under or hemmed. 3. Fold the pocket in half as shown (B). 4. Sew a row of straight stitches 1/2 inch inside both sides of the pocket (C).

10 Bosun s Chair Kit 10 1" 1" 9.2 Create Cargo Space 1. Measure 1 inch up from the bottom folded edge and 1 inch from the side seam. Mark an X in the corner where these 2 points intersect (D). Mark a matching small X on the back of the pocket. 2. On one side, pull the front of the pocket away from the back of the pocket at the 2 marked X s. Sew a row of straight stitches from X to X across the corner of the pocket (E). 3. Repeat this step on the opposite side of the pocket. 4. Flip the pocket inside out so the seam allowances are on the inside (F). 1/2" 1/2" 1" 9.3 Velcro Closure 1. Cut a short strip of Velcro and separate the 2 sides. 2. Position the loop side of the Velcro on the inside of the top flap 1/2 inch inside the edge. Sew a row of straight stitches around the perimeter of the Velcro (G). 3. Position the hook side of the Velcro directly opposite the loop side on the outside of the pocket 1/2 inch away from the edge. Sew a row of straight stitches around the perimeter of the Velcro (H). 9.4 Bind Raw Edges 1. Finish the raw edges of the pocket with binding (I). Fold the binding in half and sandwich over the top pocket edge and the flap edge. Carefully sew in place with a row of straight stitches. 9.5 Attach to Chair 1. Position the pocket on one side of the chair 1 inch below the webbing strap. 2. Sew a row of straight stitches along the hinge line of the pocket (J). Reverse (bar tack) over the stitch ends to lock in place.

11 Bosun s Chair Kit Tool Loops (Optional) 1-2" 10.1 Cut Webbing 1. Lay out a length of 1" wide webbing. 2. Cut a length of webbing 18 inches long using a hotknife Attach to Chair 1. Fold one end under 1/2 inch and position 1 2 inches below the webbing strap on the side of the chair without the pocket. 2. Sew a row of straight stitches across the folded edge (A) Create Loops 1. Create a loop large enough to hold various sized tools and sew a row of straight stitches to tack in place. 2. Repeat to create 4 8 loops across the length (B). 3. Fold the last 1/2 inch of webbing under and sew a row of straight stitches across the folded edge.