Spence
There could be more than one reason. Frankly, this problem has not shown up on my old boats’ sails, neither Malena at 32sqm, nor Johanna at 48sqm , and not on my newer boats either (Broremann, 10sqm and Frøken Sørensen, 20sqm). However, I think I spotted a little hole in the sail of Edmond Dantes (Odyssey III, 48sqm) last summer.
· I guess the sail cloth could be one factor. Johanna’s and Malena’s sails were nylon, so although the sun is hard to it, it seems to be quite resistant to rubbing/chafe.
· The slippiness of the mast’s surface could also be a factor, and also the mast’s diameter - bigger diameter leads to bigger contact surface and reduced chafe.
· Could a naked aluminium mast rub the canvas harder than a painted mast? I dunno.
One sensible thing to do would anyway be to pad the battens well at the mast, but that requires making new and wider batten pockets there. The padding would at least dampen any clang-clong noise, but hopefully the pressure on the sailcloth trapped between the battens and the mast will also be much reduced. My un-informed hunch is that this is the key to reducing the chafe.
Arne