Replace them
Sails are designed to take significant loads and survive by directing those loads to specific reinforced areas. This is why when you look at some modern designs you'll see the seams running so that the threads in the fabric act like cables running out to the reinforced patches. Battens were developed to support the sail outside the triangle describe by the foot and luff of the sail. Some of the batten is inside that triange, some is outside holding up an arc of material that could not otherwise be used. This is called roach. The sails is expecting those battens to be there. The tension in the material was set up for the battens. Remove them and you will change the loading on the sail and pull it out of shape. It is a lot more cost effective to replace the battens than it is to replace the sail. Measure the batten pockets on the sail. You need length and width. Go to your favorite marine supplier. They'll be able to help you. Get your batten slightly long and take them to the boat. (If you can bring the sail to the store you can save a step). Slide them into the pockets and mark then cut to lenght. The idea is that when you secure the batten in the pocket there is a slight amount of tension on it. Good luck - Justin - O'day Owners' Web
