I am replacing a very old sail cover with a Stack Pack. The Main on our C&C 35 Mark III uses a boltrope. Most Stack Packs I'm familiar with are either attached to the Main or the Boom. I would like to join the 2 sides of the stack pack to a narrow strip of Dacron the length of the foot of the sail, place the Dacron strip under the Main's boltrope and install the assembly as I would have installed the Main itself. Has anyone done this? I can't test my idea as my boat is stored 700 miles away. Thanks for any comments.
If I understand correctly, you are talking about the foot of the sail. Trying add more cloth in the boom track might be difficult and would certainly increase the friction in the track which would adversely affect the outhaul, it would be much harder to adjust. One problem is capturing rain water. With the bottom of the stack pack is closed water will not drain out.
It would make more sense to convert your sail to a loose footed sail. It would be a relatively easy conversion, remove the lowest panel and reinforce the edge.
It might be possible to run nylon straps under the boom to connect the sides.
Talk to your sailmaker about your plans or contact
Mack Sails, they probably have the most experience with stack packs.