Thanks folks. This project is turning out to be like watching the X Files. Every episode just adds more questions!
Fusion, regarding the foresail: it seems to me regardless of how you add a foresail it's going to act as a forstay, restricting rearward bend in the mast. It's attached to the mast topper and the bow, whether it's a furling sail or a hanked sail. How did you decide how loose/tight to make it?
I gave up looking for new hanks and decided to make my own. I "borrowed" a length of my sons hotwheels track. It's made of very flexible plastic. I cut 1"x 2" strips out of the track, drilled holes on either end, and fastened them through the existing holes in the jib using stainless machine screws and washers. I'm going to throw on some fender washers to keep the hanks from tearing at the holes.
I could probably go back to the PVC furling idea NOHUHU pictured now.
Regarding both stays: I have stainless clips on both ends of each line that is rated at 90 lbs working load, according to the packaging. Is that enough? Or should I get something with a higher working load?
Spinnaker: how do you have that attached and how do you have it rigged? Seems like there is a lot of talk and information in your thread about jibs but not so much about spinnakers. Wouldn't you need 3 or 4 lines for a spinnaker?