We have 7+5 existing, to be replaced with only 10 new. So we keep 2 existing to make up the shortfall, possibly +1 spare. Leaves 9.
"Blondie" has a prior option to purchase 6. I think he wants 4m lengths. Price yet to be negotiated.
Any good?

I have sourced 65 x 3.5 6261-T6 from Ullrich, which is our preferred candidate at present. Lengths are 6 m, which is another requirement as our battens are all longer than 5 m, the other standard length. This material is a standing order by a Tauranga company, that has agreed to release some of the stock to us. 

We now have lots of 38x3 tubes available for anyone interested. :)

Walter &Estelle 

Walter,

I used square section GRP battens for quite a long time, and over many ocean miles, the edges were chafing through the sail pockets.

Also, square tube is not as good as round tube in terms of strength per Kg.

My calculations give these results:

50 dia x 3 round tube: weight 1.2 kg/m section modulus Z = 4903

50 x 50 x 3 square tube: weight 1.52 kg/m section modulus Z = 5904 ( on the diagonal), 8340 (perpendicular to a face) - it's strange-but-true that square tube is weaker when loaded on its diagonal.

63.5 dia 3 round tube: weight 1.54 kg/m section modulus Z = 8222

A square batten tries to rotate to the orientation in which it can bend most easily, which is on the diagonal, so that presents an edge to the mast - not good.

So you'd get better value from a round tube. If your pockets will accommodate a 50 x 50 square tube, they will also accommodate a 63.5 round tube, and that's what I would go for. But Pacific Spray being so heavy and stiff, I'd make the upper battens from bigger tube still, if they'd fit in the pockets. 

An old topic, re-awakened.
Pacific Spray (20 T Roberts Spray) has 38 mm diameter alloy (apparently double-sleeved total wall about 3 mm) battens on the 600 sq ft main and the 380 sq ft fore. Lengths are < 6 m.
As we are preparing for our offshore trip and haven't had a serious shakedown in home waters, we are contemplating stronger battens, especially the upper battens. We have increased all pockets on both sails to 60 x 60.
Ulrich here in NZ can only offer 50 x 3 mm 6061/T5. Or alternatively 50 x 50 x 3 mm 6261/T6 square. I can identify with the latter.
Square or round? Scantlings?
Any views or referrals will be gratefully received.
Thanks in advance.
Walter & Estelle

I was trying to get to Karmsundet to race on saturday. The wind was 35 knots and coming from 3/4 rear and I started with 2 panels down. That was a bit much as the wind increased to 38 knots, and I took down another panel. As poor Edmond was trying desperately to surf, I had to bring down another panel. I was now 4 panels down and had 8-9 knots falling down the waves. I tried to take an inshore route to awoid the biggest seas, and my heart sank a bit when I met the ferry that crosses the relatively open strech of water. I know when they stop going, it is rough. I came to the end of the shelter and looked at the seas running, the line between being a hero or a fool is quite thin, so I decided to seek cover and hope for better conditiones next day. The wind became tamer the next day but too late to get to the start. I tried if I could make progress agaist the wind, and I could. It was more a rodeo than a sail, though. Reading this thread make me think: I did not have any problems with the battens, nor the rather flimsy sailcloth we use here in Stavanger. My thoughts were more in the way of loosing the mast by a break in the mast step. Then the mast would act as the biggest can opener in the world, and to quote Arne: That would be a sad day on the fjord. My mast and sail is direct copy of Arnes.