Hey Baytown Bill,
You might want to chat with the folks at Banks Sails over In Kemah. They may have some ideas about how to economically refit your sails. They are good folks and all sails are made in their loft right there. They have made a few sails for me and done repairs on the old set of sails. I have been very pleased with their work.
Thanks, Banks actually fixed the loose stitching and replaced the leech line on my jib last month. I bought a code 3 from them in 2017 that was made in their loft, not on the other side of the planet. I should have had them make my new main and jib back when, but I fell for an email promising a huge off season discount or something like that. If the main does need a repair/recut, I'm sure I'll take it to Banks.
Also, curious, have you had any discussions with the manufacturer (franchisor) up the food chain from the local loft?
I did send an email to the name brand. I don't think the local loft was concerned even if they were contacted. I have met other local bay sailors who have had similar issues with them. I'm sure if you're buying tens of thousands of dollars worth of racing sails every couple years, your service is much better.
Never had brand new sails and I'm concerned with the issues I'm already having and worried how long they will last. I'm not out crossing oceans in a perpetual gale, but I do race a lot and the sails are up almost every weekend. The UK sails the boat came with were over 15 years old when I replaced them.