checked mine as soon as I read your post and I to have all 5mm wide battens. The other thing is the week before last I contacted my dealer because the second batten cap had put 2 holes in my sail when it furled up really tightly. I have a feeling that if I had the right sized batten to start with this may not have happened.
I was coming in because it started getting real messy the wind was gusting from all directions. I had the sail furled in almost all the way with the wind behind me pushing to shore when the sail unfurled and bagged right out and I was heading for mangrove trees, of course I had to furl the sail in really fast and becuase of the wind filling the sail it was really hard to do so. I noticed the sail was really tight when I tried to lash it with the cord and found the cord was way too long as in it wrapped around the sail one and a half times. At that point I massaged the sail to loosen the tightness of the wrap on the it so the cord would work.
At home I hung the sail in the shed to allow it to dry this is when I found the holes in the sail. The sail had wrapped so tightly the second batten end cap pierced two layers of the sail and left a visable dint in the third layer. The end cap is really sharp on the inside edge and I think it angled enough under pressure to do the damaged.
I am waiting on a response from Hobie via my dealer, I am wondering if this would have still happened with the thicker batten installed http://i1253.photobucket.com/albums/hh5 ... yak101.jpghttp://i1253.photobucket.com/albums/hh5 ... yak110.jpg
I am wondering if this has happened to anyone else