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are your fittings all 3D printed things you've made yourself? the mast cap with the double fairlead and rings for the jib the red mast cleat(?) fixture at the front of the jib bowsprit (that sits over the handle) fixture connecting the jib bowsprit to the mast jib control fixture (that you...

Found it:

Can you post a video description we could search for? I can post the link for you.

SLO sells a Super Porpoise sail… but it’s over $500. Ouch. https://www.slosailandcanvas.com/super-porpoise-sail-white/ You’d probably be just fine using the slightly smaller Sunfish sail (you can get a brand new race cut Sunfish sail from Intensity Sails for <$150).

You might see if international shipping from Intensity Sails is reasonable overall cost instead of trying to make your own https://www.intensitysails.com/rastprsafors.html

This pamphlet is a good start: https://my2fish.files.wordpress.com/2009/10/learn-to-sail-in-3-days.pdf Steve King has several very good videos, here is one:

yeah, I cheated and used Google translate. :)

https://westcoastsailing.net/content/parts-locators/parts-guide-sunfish-sailboat-laser-performance.pdf

I'm including 2 files - one is (4) 8.5x11 pages that you print and glue/tape together to make the logo. The other is a 24"x36" file with 2 logos mirror image - if you have a way to plot that full size, that's the easier way to go. Have any engineer or architect friends? They all should have...

by far the coolest method to repair small holes in your sail was by @Breeze Bender https://sailingforums.com/threads/sail-repair-pics.39618/

If you add a horn cleat to the mast, then there will very little load on the tail of the halyard, and you could probably just bypass that small fairlead and tie the tail of the halyard on your existing horn cleat (just to make sure if you turtle the boat the mast and sail always are connected to...

Ken, if you trouble finding the Bahia, have you looked into an RS Quest? I think they are similar and the Quest might be easier to find.

The bolted on pulley could fail under heavy load - the integrated fairlead in the modern mast cap is less prone to failure and works quite well. Seems like every couple weeks someone is posting on here asking about masts - apparently you and @Alan S. Glos are hoarding them all. :-)

Heating it up might help, but I'm not sure how easy it would be to heat it with it still attached. sun1fish's plan should work, maybe a little bit of hammering as well.

Have you used that version but switched the fairlead out for a ratcheting block?