Dacron sails can be flaked and gently folded into a pretty small package.
Here's the proper way, the video ends abruptly but after you flake it as shown, then bring the ends to the middle a couple of times until you end up with a square and fairly flat package.
I've shipped several Hobie 18 mains and the key to reasonable UPS shiipping price is to get the total dimensions of the box as small as possible.
So flake/fold the sails into a 24x24 inch footprint, then cut down a standard 24x24x24 box till it's just tall enough to close. If you do it right you should be able to get it down to something like 24x24x12 or less which will vastly reduce your shipping cost.
Even a set of Pentex sails I bought from Whirlwind were shipped to me new flaked like this and it didn't seem to have damaged them, however I did prefer the way EP shipped, rolled in along box. You could do the same if just hate the idea of folding the sails, or if you are also shipping the battens. The key there is to make your own custom box and roll them as tight as possible. The box EP used for main and jib rolled up together (without battens) was only about 6x6 thick.
Whirlwind
EP Sails
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Damon Linkous
1992 Hobie 18
Memphis, TN
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