Hi, This is my experience on how to repair a batten. I'm no expert but this is my take on how to remove and repair a broken batten.
I would always take care in rigging and packing my sails so to see my batten break mid session i was disappointed, the sail is a 8.4 which is just over a year old. I suspect I had too much batten tension so on the flip of the sail the bend was too great and snap it went.
Does anyone else adjust your batten tension each time you rig, I tend to adjust them each time. Hope the vid is helpful to someone with the same problem. Regards Walt

Sometimes if I use a newer sail in over powered conditions, I will look before derigging at the sail, occasionally I have had to tighten some battens a second time.

If you're rolling a sail and the battens aren't straight I'd suggest overtensioned....

A metal tube slightly larger diameter than the batten, slide over the broken end, twist and pull.

Imax1 thats a brilliant tool, if only i saw this idea before, the drill could of not made an appearance. i will be making one of those for sure for next time but hoping there's no next time.

DarrylG said..
I know the Severne sails actually have small section of the stitching on the batten sleeve in the luff pocket removed. Then if you ever have to remove a broken batten you can simply slide it out from both ends

I took the 3/4 length broken batten and flipped it around and jammed the white tipped end into the broken off end of the tube batten that was in the batten sleeve and then gently pulled/wiggled the 1/4 length broken batten tube out.

I couldn't watch it, that drill standing on the sail waiting to fall over and make a hole in it was to much

I have removed tons of broken battens, your way of milking the batten out is good unless it splintered, then it gets stuck even more, for normal pockets you can also use a wooden ruler.

One to try first is to glue or tape some tube batten over the end of the broken batten or a longer batten and insert it into the pocket so the broken part jams in the tube then pull it out.

Or unpick 3cm of batten pocket and pull the broken part out the side of the pocket, then stitch the pocket back up by hand or get a sail maker to do it for you.

I would avoid drilling a hole in the webbing, it looks strong but with load will eventually blow out, if it is a plastic interface camber batten end they are fine to drill a small hole in, but i would keep it to 2mm. The best way to get the batten out of the end is to scrunch up the sail between the snap and the mast sleeve so the broken part of the batten slides up the pocket a little then you grab the batten closes to the leech and hole it while and straighten the pocket out, slowly do this and it will clear the stiff end of the pocket.

Great video, the peg trick will come in handy one day.