Lube
John: If what Dan suggested, having a slug stop hold the slugs above the opening in the mast, doesn't help. I have another suggestion. I don't know anything about having the halyards led back to the cockpit, but I do know that the slot that the slugs go into must be lubed. I lube mine every spring. In the past I used a silicone lubricant, but now I use a Teflon Triflow lubricant. I feel this is almost a safety issue, because if you can't get your main down when a storm is approaching, you will be in for a real exciting time. (Once we chartered a 30 footer, and couldn't get the main down, and it left me with a really bad feeling, and a little crazy about this issue). Anyway, the way that way I lube the slot is to get a cotton ball, and wrap a piece of soft copper insulated wire around it (telephone wire), and soak it with the lubricant, then lube the slot up and down a few times. The sail will just fall down when the halyard is released. I'm not sure if this is your problem or not, but I hope that this helps you or someone else.West Marine also sell the slug stops that Dan mentioned. I usually have to file one of the sides flat to get it into the opening. Aldo