Tent-building, and a fabric mystery
Feb. 25th, 2024 11:38 pm![[personal profile]](https://www.dreamwidth.org/img/silk/identity/user.png)
That served us for many years: we've replaced many of the ropes, and replaced the valence once or twice, but the roof and walls have pretty much survived. But they've gotten thinner, and less water-resistant, and more faded, and around 2013 she suggested we build a new one — another two-pole oval tent, slightly larger than #2. So I started designing, and bought the fabric (50 yards of 84" Sunforger canvas) in April 2014. But it was never a top priority, so I made only minimal progress every year, and it dragged on.
In 2015, Will McLean died and left us his beautiful round arming pavilion (#3). It's about the size of our #1, but better-made (largely by Mac & Marianne); not big enough for the two of us to camp in with instruments, but it works nicely for daytime living history shows.
In 2022,
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Anyway, I'm very much hoping to finish tent #5, the one we started designing in 2013, by this Pennsic. The roof was finished in September 2023, and I turned my attention to walls, which are simpler. There will be two wall pieces, overlapping at front-center and back-center so we have a front and back door. Each wall consists of two rectangular door pieces and eight trapezoids to go around the semicircular ends of the tent. So I've been cutting trapezoids. More precisely, I've been cutting rectangles from the bolt, pre-washing the rectangles, and then (after they've shrunk as much as they're likely to) cutting two trapezoids from each rectangle.

Selvages are top and bottom edges of this diagram. The trapezoids are supposed to be 27.5" at the narrow end and 34.5" at the wide end, a difference of 7", so an isosceles trapezoid should be 3.5" off the perpendicular on each side.
But where is the perpendicular? When you pre-wash fabric like this, the cut edges come out somewhat raveled. So in order to make sure I was cutting proper isosceles trapezoids, I spent at least an hour finding weft threads that started or stopped part way across the fabric, and pulling them the rest of the way out, until I had a single weft thread forming the edge all the way from selvage to selvage; then I could use the corner between that weft thread and the selvage as a consistent starting point for the measurements in the diagram.
And it didn't work. Every measurement was right, but the trapezoids were decidedly non-isosceles. Whether I folded vertically down the middle so the selvage matched itself, or crosswise, one selvage to the other, one bias edge always stuck out several inches farther than the other. (We're talking 2-3" off, over a fabric width of about 80" after shrinkage, so that's maybe a 2° angle.)
This happened for at least half a dozen trapezoids. I rechecked the arithmetic, measured everything three times, and it kept happening. The only explanation I've been able to come up with is that the weft threads are consistently not perpendicular to the selvage.
So my revised cutting method is "fold the cut edge toward the center of the fabric so both selvages match themselves, even if that means one end is folded several inches farther than the other; use this perpendicular fold as a measuring reference." Which has the advantage that I don't have to spend half an hour pulling out weft threads, and the resulting pieces look isosceles. But I worry that they may stretch weirdly because one bias edge is farther off-grain than the other.
Have any of my sewing-and-costume colleagues run into this problem?