I am sewing on "WeatherMax" fabric (making golf flags) - an outdoor, lightweight, material; in the wind my fabric is fraying and splitting. Was it the needle? Is it the fabric? is it the machine? Did I cut it out in the wrong direction?I have tried all kinds of needles to no avail! I have thread at 182 m..... I have completed 54 flags that will all need repair! What do I now? I have been sewing for over 50 years! The fabric is not heavy - but is man-made not natural. They say it will even make great boat covers. I have made boat covers out of Sunbrella before on a Kenmore machine ... I don't understand why my this is happening. Plese help if you can. thanks.

Cut it with a hot knife.

First, why are you using a plastic/coated fabric for flags? I would suggest ripstop nylon, as it's easier to sew and holds up to the wind nicely. Are you hemming or binding the flags? If not & that is where your problem is..I would use a plastic adhesive on the edges.
I use ripstop, and hem any flags & banners I've made.
Weathermax is a plastic, you are most likely breaking threads in the fabric when sewing it...maybe a ballpoint needle will help? I haven't sew with the Weatherstop fabric.
There is a website that is a dealer for Weathermax...they have a contact email there...http://www.bruinplastics.com/weathermax.html

PS...When I make my flags/banners using ripstop nylon, I also do applique for the letters/numbers...works great using just a zig zag stitch to secure them.

Hi. Interesting problem. For outdoor materials (and advise on sewing on outdoor materials) I rely on Sailrite (http://www.sailrite.com/) and interestingly, couldn't find Weathermax fabric on their site. I would contact their forum (http://forum.sailrite.com/) and ask the question there. Matt Grant (I think he runs the sewing part of the forum) is extremely knowledgeable and helpful.

Sorry I don't have anything more for you,


Robbie