Great Ideas....Thank you.
The bolt rope channel is still in a C shape. The areas where the rope doesn't pull through look to be 1/4" wide, but where the rope pulls through its 5/16 or so.
The wider slot looks to show that it is bending open due to "FATigue" as opposed to a crack that would signify a failure.

Thats why I thought filling the slot and CAREFULLY routing a new groove to meet factory specs is good. I'm a bit concerned that a slight slip with teh router (even if I use a custom jig) would be a major deal. The forum suggestions are aweome to get the alternative ideas flowing.

I'm also considering the idea of a soild fiberglass batten epoxyed into the existing track with room left in strategic places to thread in the new tramp lacing.