". . . we contacted a local dealer and they did say they could still make custom sails to match our main but he said it takes a while to get them and they are a lot more expensive!
You got some bad information. A custom jib is not "a lot more expensive". I looked up the prices of jibs on the Mariner Sails (Dallas Hobie dealer) web site. The cost of a turquoise jib, part number HC20992071, is $499. The cost of a special order jib, part number HC20992991 is $599. If somebody wants custom sails, I doubt they'd consider an extra $100 to be "a lot more expensive."
I've ordered custom sails through Mariner Sails before, their service is excellent. Follow this link for their prices on genuine Hobie sails, http://shop.mariner-sails.com/Hobie-16-Sails_c251.htm
. They have their own loft and you'll see that they also make Hobie 16 sails in house and they're a bit cheaper. Keep in mind, however, that if you want to get into one design class racing, you should buy the Hobie-built sails from them so you'll be class-legal. Mariner Sails will ship anywhere. Talk to John or Aris and tell them that Mark Van Doren referred you to them.