Dave,
I looked into that. The furler mechanism itself is working very well.
The problem may be the cut of the sail. It almost seems as if there is extra material close to the luff. When the thin bolt rope is in the groove of the furler rod there is a fold of extra sail cloth that "folds" up backwards as that first roll of sail cloth goes on the furler.
I have the halyard very tight. And even if I pull the foot very tight I still have that loose cloth. If I pull down too tight on the main sheet to try and tension up the sail some it gets to a point I can't roll any sail in at all due to excess tension.
Almost seems like the belly of the sail is too big causing that excess material near the luff seam to fold up wrong and jam up the works.
I am going to call the sail company rep I have been working with today and see what he thinks.
Cheers,
Jim