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PC #29 came to me with two square one problems, neither of which may apply to your situation, but anything's possible. First, all my blocks for the halyards were for 1/4" lines, and the halyards were 3/8". This caused a lot of friction. Solution: larger blocks or smaller halyards. I chose larger blocks. Second, the luff of my OEM sail was 5 inches too long. Either the boom was too low and banging the gallows, or the throat would always have the "too loose" wrinkle. Solution: longer mast or shorter luff. I chose shorter luff. Five sails and three sailmakers later, problem solved. Yes, I measured very carefully, confirmed my spar lengths with Compac, and send all three the same measurements. The third sailmaker finally got it right, on the second try. They insisted on using the measurements in their computer for their first attempt, and, guess what, I got another sail that was 5 inches too long in the luff. For their second attempt, they acquiesced and used my measurements!
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