cutting Kevlar easy, but I cut Kevlar with cheap office supply scissors.
Get the Kevlar well back in the jaws of the scissors. Use short cutting strokes, and with each stroke, pull back a little bit during the stroke. This helps the scissors jaws saw through the fibers rather than just pushing against them.
This is a somewhat tedious process, but you don't have much to do.
The reason I specify oval patches rather than square or rectangular is that a straight edge leaves a stress riser. A lot of times it may not matter, but when one wants the *best* patch, the layers should be round or oval.
First put down your one or two layer Kevlar patch. Then fray the end(s) of your webbing. Probably the epoxy in the patch will have hardened. If so, clean it with soap and water or rubbing alcohol to remove amine blush. Then epoxy the frayed webbing end(s) down. You may want to tip the boat hull so the webbing ends want to stay down, and you may need to put some food wrap or wax paper over the wet frayed ends and apply weight to compress the fibers.
Full Size Sail Rig
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