Some sails I'm very fond of and have plenty life left in materials. But lately I've had 2 2006 KA's break the downhaul pulley.
with these I ditched the 8mm tube and replaced with a 8mm 316 SS bolt but Tig'd the washer on to keep compact.
would love to hear other tricky repairs to keep kit keeping on.
^ I had one of those booms and, following a tip on this site, I put O rings in the grooves where I wanted it to stay. It held the cup in place and the cup compressed the O ring so it stayed there and it was still adjustable.