Nope, the luff track is fine. The old blown out sails run up just fine. The rope with its sheathing are slightly larger on the new sails. And when it gets stuck up there at the comptip, it gets smooshed, which makes it larger still and makes the problem that much worse.

The root of the problems seems to be that the top of the bolt rope is flat, it's a hard edge at the cut. Maybe something could be sewn on to give it a tapered edge so it slides into the comptip easier. Has anyone had a similar problem? And solved it? Thanks.