Sail Repair At Midway
The staysail took a beating on the passage from Kwajalein to Midway. Three days with a storm on the nose took its toll on the sails. One of the interesting problems was caused by the back of each piston hank digging into the sail and chafing through. The result was a small straight cut behind each hank. I was concerned about the long term stability of the sail and so applied temporary patches behind each hank and then applied webbing to spread the load in case the chafing returned. The repair held up well and no additional problems were found upon return to LA. 
When the staysail halyard block failed a week out of Midway I had to rig up a temporary fix to keep the staysail hoisted with sufficient tension. The result was the head of the sail chafing against the inner forestay. Luckily the damage was pretty minor and the inner forestay was just fine. Rick brought out a new block to replace the failed one. It turned out that the block which was up the mast was a temporary block which was not up to the load. The replacement was the correct block and gave no further trouble.
Due to spending most of the trip from Kwajalein to Midway double reefed there were a couple of chafe spots on the mainsail where it rubbed against the external track. These were repaired with sticky sail tape and then sewed down. This one was especially difficult due to going through the sail right at the tack and thus many layers of fabric.
Rick and I spent many hours repairing the staysail. It is the backbone of the heavy weather sailing inventory and needs to be bulletproof. The head, tack, and clew were all inspected, each of the hanks was reinforced due to the chafe caused by the piston hanks.
Careful inspection of the Genoa resulted in finding an issue with the head of the sail. Apparently the exposure of the stitching at the head of the sail to the sun while on the roller furler had result in significant degradation. Each of the machine stitched threads broke easily, the hand done stitches were of a heavier thread and held up fine. So I spent several hours replacing the machine stitches with hand done stitches with heavy sail thread.