1. Could you tell me which of these I need to get? There seem to be a lot of choices...http://www.coolaroousa.com/view-products.do?category_id=Shadecloth
Any 70% should work, you choose the color
2. Could you provide the template for your best design that does not require new holes or the least modification to the hull?
My AI template is available to download free on my website, near the bottom of the page here: http://www.kayakingbob.com/sprayskirt
I never created a TI template, but it's just the AI template cut 4 inches shorter at the front, just change the outside line angle so it's the same width at the point.
3. What stitch pattern will provide the most strength/durability?
Use polyester thread for UV resistance, and use a stretch locking stitch, if the machine has one.
Good luck and post your results.
- - - - - Hobie Island Sailing since 2006 - - - - - 2011 & 2015? Hobie AIs and a 2012 TI