OK, time for an update.
I've read this thread several times, took notes and added a Cunningham. Now, I don't get to play with a full main often. We've had good winds so I've only sailed without a reef 3 times in 14 day sails this year and only two could I really play with different trim methods.
While the Cunningham definitely helped, the post by THECUSCUS pointed me to what I think is the real problem.
The sailmaker did not cut the tack with the proper offset.
They also forgot to put the O'day insignia on the sail as requested. They sent me two when I called them about it so I laid the new sail over the old one to get the proper placement. Looking at them I noticed that the tack on the old sail was cut angled away from the mast from the bottom sail slug to the tack cringle. The new sail had less sail slugs and had a square cut tack.
When I installed the sail I flipped the gooseneck slide so the ring on the slide used to pull the gooseneck down was now on top. I then shackled the tack cringle to this ring which held the tack closer to the mast. This helped but not enough. Also I found that the cunningham, which I had run down to a block on the port side of the mast organizer pulled the tack to port instead of straight down. I moved it to a center point and it worked better.
I then tried using a long D shackle to shackle the tack cringle to the ring. I also lashed the tack and shackle to the mast to keep it close. I re read JackDaw's instructions for raising the main and noticed that even though the outhaul line was loose, the clew strap was so tight it didn't really loosen up. I fixed that. I also checked the slugs and they slid easily.
This time I was able to get a good taught luff when raising the main.
The outhaul still pulled the tack away from the mast a little but the wrinkle was much reduced. After a bit the bottom of the luff did loosen a bit so the Cunningham worked to tighten that. Not sure why the luff loosened. Maybe the line slipped in the clutch? I don't think I can be sure until the tack angle is fixed.
I called the sailmaker and he said it was strange that an offset was needed on a small boat but to measure how far aft the tack pin was from the aft edge of the mast. He suggested just what I had done, to try lashing the cringle to the mast for the season and send it back to be fixed in the off season. I didn't push why they didn't know it needed an offset since they supposedly were building it to O'day 25 specs except for the options of a loose foot and 2 x 2 batten setup. Lesson learned there.
I'll also have them install a Cunningham cringle.
I wouldn't have figured all of this out without the help from you guys so much appreciated.
Photo 1- The original sail where you can see the tack angles aft from the mast.
Photo 2- A close up of the gooseneck and shackle holding the tack forward more than the pin would.
Photo 3 - Some improvement to the wrinkle and the Cunningham really helped.
Photo 4 - I tried a long D ring and lashing to hold the tack closer to the mast.
Photo 5 - Big improvement in reducing the wrinkle.
