This is a good suggestion.move the fairlead car farther aft on its track
That’s my guess too. One thing that can happen on older sails is that the leech can stretch out and no longer be under as much tension as it should. It looks like that could explain a wrap like that. Moving the car forward might help keep more leech tension so it furls when it’s supposed to instead of bubbling out while the rest of the sail is wrapping.I suspect that this is a very old sail that has lost its shape.
Either way you should experiment with the fairlead cars as Joe has suggested
Good catch. I missed that too. I think you’re exactly right - there’s a lot of cloth and stitching at the head there and not a lot of force available to make it curl, so that could explain it.The op stated that it’s a new 140 genoa, in which case I would suspect that the head patch is stiff and doesn’t like to be bent around the foil. I have a similar problem with the clew patch on my new mainsail, it’s very stiff and makes closing the sail cover very difficult.
Yep. We must had the same problem with a brand new sail. After a while it rolls better (at the expense of a permanent curl when unfurled).The op stated that it’s a new 140 genoa, in which case I would suspect that the head patch is stiff and doesn’t like to be bent around the foil. I have a similar problem with the clew patch on my new mainsail, it’s very stiff and makes closing the sail cover very difficult.