Wind tunnels and windage

Matt Cornwell and Leigh McMillan testing the aerodynamic properties of their sailing kit © Harry KH / Land Rover BAR

Even the most casual observer can see that the America's Cup has changed beyond recognition. The new boats are faster, more extreme and much more athletic. The foiling multihull now demands sailors with endurance sport capabilities; and with speeds up to five times quicker than the previous monohull designs the sailors need to be better protected from the extreme conditions.

All this requires a completely different approach to the clothing that the sailors wear – the traditional attire of foul weather jackets and trousers is long gone, now everyone has a wetsuit on. And not just any wetsuit, helmets and body armour have been added, with spinal boards to reduce impact injuries, and quick release knives and spare air in case of a capsize.

Watch the video: behind the scenes with the team at Land Rover's testing facility

All this equipment could end up very bulky and awkward, but the speed and athleticism of the new boats means that aerodynamics and freedom of movement are even more important than before. Nick Hutton is the sailor assigned to work with Official Supplier Henri Lloyd and Technical Supplier Spinlock to make sure that the team at the sharp end get what they need.

The result is a new Spinlock lifejacket, the BAR T2 Personal Floatation Device that will be combined with Henri Lloyd technical apparel to produce an aerodynamic, comfortable set of gear.

"We started with a traditional life jacket," explained Hutton, "and the first aim was to improve the aerodynamics. What we've done to reduce the drag is to weld the rash vest material onto the life jacket to eliminate any air gaps, and maximise the aerodynamic efficiency as much as possible. Then we reduced the foam so it was just above the amount required by the rules to keep the bulk to a minimum, integrating and recessing all the equipment to be as low profile and aerodynamic as possible."

The innovation and technology partnership with Jaguar Land Rover (JLR) meant that the team then had the opportunity to test the new equipment in a wind tunnel normally used for automotive research. Two of the team's sailors travelled to the facility in the Midlands to see what they had achieved with the changes so far, and where the gains were to be pursued in the next design.

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A sugar-based vapour highlights the sleek design of the team's Henri Lloyd and Spinlock kit - photo © Harry KH / Land Rover BAR