Then I tried putting up the main yesterday. I have to admit Karen noted that the grove on the new luff was a bit narrower. 'That's a good thing', says I. "Remember how the halyard line used to get trapped in the grove"? Of course I already fixed that with a block and a thimble.
So I tried to thread the main. the first foot or so, just a little tight but doable. Then comes the first reef with its reinforced cringle. No go; tighter than "Dick's hat band" to quote my late Dad!" Tight, tight, too tight!!
Now I have a real problem. Not a little one, a big one.
I tried a short piece with a bit in the Dremmel tool. Too wobbly! "Looks like a guide and a router is needed. How do I do that," I muse?
Well, I just happen to have a very good friend who is a master woodworker and retired engineer (ME). He is a master at making jigs. "I'll call Paul in the morning," I told Karen.
Here's the before and after. Before the clean up. Plenty wide for the sail to slide easily.
Thanks Paul, W4KLY. Did I mention he is a very skilled ham radio operator and sends and receives Morse code like a commercial operator? My mentor, Paul Kelly, W4KLY, I'm proud to know you and thanks again!