Next time start at the top... don't try to pull the mast out at the bottom.
The sails have "luff curve" sewn into them to create the shape required to induce "draft" for a properly functioning sail. This binds on the straight mast.
Grip the sail / mast near the top and then grab the sail further down. Pull your two hands together so you bunch up some of the sail material. Then push the hand grasping the mast, through the bunched up sail. Repeat several times to get the mast past the curved sail tolerance area.
Director of Parts and Accessory Sales
Warranty and Technical Support
Hobie Cat USA