I was in the same boat, pardon the pun, and went to the sail maker my buddy gets his racing sails from. I like his sails they work well on Wednesday nites. Theses were my choices.
Cross-Cut Dacron Main 493 sq.ft. 7.5 oz $ 4,750.00
Tri-Radial CLP Laminate Main 493 sq.ft. $ 5,898.00
Either of these would be configured with the following:
— if Dacron Dimension/Polyant fabric, made in Germany
— if Laminate, Challenge, Pentex scrim, Double taffeta
— UV Dacron clew cover (much lower bulk than Sunbrella)
— Oversize clew cover so you don't have to roll as much sail into the mast.
— UV strip up the leech
— Radial corners
— Harken Clew Block
— Spectra leech line with the tail led to the bottom edge of the clew
— Draft stripes
— Numbers if desired
— Sail bag
I went with the laminate and would do it again in a heart beat. It should allegedly last ten useful years. It is on a hunter 41 that weighs 24,000 lbs with fuel only. I guess we run around 27,000 on any given day and those sails:
Furl in and out effortlessly compared to 6 year old dacrons
Hold a perfect shape even without battens
Allow me to really tension the foot which lets me keep full sail in higher winds with less heel
Are lighter in weight which is nice in fall and spring when I shoulder them
Lets my boat run to hull speed more times than not
If they had issues and were only 5 years old I would repurchase them in a heart beat. They make my big clunky cruiser a joy to sail and they look good doing it. Just my opinion.