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Interesting. Bummer your main ripped that way but at least now you'll have it reinforced!
Yes, I use the roller reefing and always tighten up the foot outhaul before rigging a reef. I never have actually considered that the leech of the sail might not be strong enough!
I have a ~10 year old dacron main (not stock) built by North Sails in Alameda (near Oakland). I told them I sail on the Bay now and then so it is built fairly heavy. I will be keeping an eye on it now!
The trick to not being overpowered is to keep the sail flat when reefed and that outhaul seems to help a lot.
Someone mentioned the mast "pumping" in heavy going. I can't stress enough (pun!) the importance of keeping your rig tuned and tight. Even with no backstay rigged, mast movement should be minimal to none. Shock loading of a slack wire coming taught is what breaks things!
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