Paul, there are two basic solutions to your issue:

1. Buy mast gates.

2. Install a "jack line" on the bottom of the luff of your main.

Hello Paul
Installed single line reefing on both mainsail reef points, but this would apply to using two lines for each as well.
Not on the boat, or would send a picture, but imagine putting a stainless ring somewhat larger than the grommet on one side and attaching a block through the grommet to the ring. The reefing line is led through this block, not the grommet. Now when the reefing line is hardened, the block brings the reefing cringle down very close to the boom, avoiding it stacking up on top of the sail slugs in the mast above the thumbscrew.
Hope this is helpful.

Paul - On my mainsail - the slugs are attached to the main sail with an 1/8 line. I am not sure what this is called. Basically when the sail is reefed the line becomes loos and the bottom part of the main moves away from the slug. I am not sure how many bottom slugs are done this way. When the sail is not reefed the line is toughs ( stretched) and the luff is pulled into the slugs. I will take some photos next time I am there. You may be able to find this feature explained on a sail maker website. Here is an image that may show how it is done [url]http://www.catalinadirect.com/index.cfm?feature=34[/url]

Haro's solution sounds like jack lines to me.

Paul - the jack line is weaved through the last 3 or 4 slugs only. Yes you should be able to change your sail ( without modifying the sail itself) so that it uses jack line instead of the luff connected to the slugs. I would think you would have to cut the slugs and remove them from the sail - you then have to use new ones. You weave the line through the sail loops where the slugs were connected and through the slugs and continue down to the last slug on the sail. Then raise the sail all the way and pull the line tight so that the luff is as close as possible to the slugs. It is similar to the way a shoe lace is weaved.

Paul,
I had the same problem with Julandra (#659). During one of the first sails after I bought her, I put in the first reef for expected heavy winds. When the winds came, the two slugs above the reef ripped out, because the reefing line was only pulling the tack of the sail down. Nothing was pulling the tack of the sail forward, to counter-act the forces from the reefing line at the clew and the force of the wind on the sail. Very poor design, IMHO. After I had the sail repaired, I changed the way the forward reefing line (at the tack) was rigged. I kept the thumbscrew in place, but added a bullseye fairlead and eye strap to the mast. With the reefing line tied to the eye strap, up through the cringle, and down thru the fairlead, the tack of the sail was now pulled down AND forward, at roughly a 45 degree angle. It worked well for the next 17 years in all sorts of conditions. I assume it is still working well for the new owner. The fact that the sail is slightly bunched up just above the thumbscrew didn't matter at all. The sail shape was flat and tight. I've attached a pic showing the fairlead and eye strap installed for both the first and second reef. The first reef line comes down on the port side, the second reef line comes down on the stbd side. Sorry about the blue color. The pic was taken under a winter tarp. The second pic shows the first reef in place, sailing in 20-22 kts apparent. The reefing line could be tightened a bit more (down to the knot?), but it was working well, as the luff of the main is parallel to the mast, and no slugs are being ripped off. The second reefing line is not rigged in this pic. Hope this helps.

Great info, Tom. Thanks for sharing.

Tom, I have never been satisfied with my single line reefing and like your solution. Any thoughts on how to handle the clew?....I have a MKII and the current single reef line exits the stbd side of the boom in an upward direction. A also have a full bimini so I don't have access to the aft end of the boom.