Matt I guess from Yakaholic's stance, it would come down to economics. Pirate
The way I see it is that a new sail is $410.
If it costs me more than 60% in "parts & labor" - more than ~$250 I might as well buy the new sail. I still get to keep the old one which I could still possible patch up.
The failure is mostly related to sun damage and to how much the sail has luffed (flapping like a flag). This brakes down the material after time.
Sail stored in house, not near a window, and carried in the bag while cartopped. So sun exposure is all from sailing use. But the sail does see a fair share of luffing and general use for sure.
Over time, with general use, the window developed many little creases.
I was out in 15-18knt wind in 60 degree weather a few days ago with the sailed reefed in 1/2 way. Sail was pulled tight to make progress upwind and after a few tacks and some luffing I looked up to see the window shredding/coming apart. Closer inspection showed the sail to be now very brittle and cracking.
Florida use averaging more than 10 hours a week for 2 years (well over 1,000 hours total). The sail cloth material looks absolutely perfect, as does the stitching, the eye & the hems.
A precut replacement sail window kit would be wonderful. My sail has a sticker "North Sails" on it.
Maybe Hobie can encourage its sail maker to provide a new window kit for sale?
I have sewn ripstop nylon for making stunt kites. So I may try my hand at a fix. I think the window size is a little overkill and may replace some of the window area with more durable fabric.
I'm not at all upset. The process happened very quickly and took me a bit by surprise. Just weighing options. Thankfully it's not summer yet.