It would seem to me, that unless you're looking for something that will last over 40 years, using aluminum track should be an acceptable solution. I believe that all the AC yachts, where the track was placed on the top of the rail, used aluminum track. For eg, see A-100.
Using Delrin plastic for the die-set on a tubing roller would great for curving aluminum track. The Delrin won't mess up the anodisation on the track. You can buy the Harbor Freight tubing roller at their stores for around $60 without a base and clamp it on a workbench.
Thanks for the input. I think if I put any additional track down on the rail I'll be going the route of using the extruded aluminum product from Schaefer. Although, if I don't end up adding more to the toe rail and will be only putting down straight sections of track I'll use the stainless steel material which will match my existing track and the cars will all be interchangeable then.
The thought of adding additional track came about last fall after sailing the newly purchased boat a couple times and finding I could not get enough tension along the leech of the 110% genoa to keep the top from luffing when sailing close to the wind. At this point I am thinking I may be able to get close to the proper angle for the jib sheet by installing a barber haul off the foot of the aft life line stanchion. At the very least I should be able to get closer to proper trim and would like to spend some time sailing the boat before I dive into too many changes.
regards,
Mark
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