My son has asked me to make him some nautical flags for his sailboat and I am researching how best to make them. Anyone ever done this before? I think the best material is going to be the SolarMax flag material and a poly thread and I think some kind of poly webbing for the gorments.

There are some of these fabrics that have better UV protection than others. It might be something that you will want to keep your eye out for :D:D:D

First you will need to get the nautical alphabet..I used some rip stop banner type fabric..or canvas, used mine around border of quilt for Outerbanks NC to raise $ for wild horse. Good luck.
hugs

http://www.gma.org/Tidings/snailtale/flags.html

this is the nautical alphabet. should be easy to copy.