Back in 2021, while I was working for Nat, I made the sails for the Ernestina-Morrissey. At the time she was undergoing a major restoration here in Boothbay Harbor. Nat and I spent a lot of time going through the entire sail plan along with master shipwright David Short.
We made sure that all the sails were built to perfectly fit the vessel by pouring over historical pictures and texts. All of the sails were made out of Oceanus, were hand roped, and had hand sewn rings.
The largest sail was the mainsail at over 2,500 square feet. We cut the sail in three parts with a four person team. After I seamed the sail we brought it to the local YMCA gym, which it filled, to check the measurements. I then spent the next five weeks finishing the sail.
In total I built a main, fore, jumbo, 2 jibs, jib topsail, fore gaff topsail, main gaff topsail, fisherman, and passage trysail. It was done over the course of seven months with other projects in between.
Corner hardware was custom made in a local forge. To build the sails properly you must have the correct hardware which today isn't available off the shelf.
I was able to sail aboard her in the 2023 Gloucester Schooner Festival and see the sails set. A lot of time and effort went into every one of the sails and it paid off.