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.
Hi Mikey100
set n forget is probably right and many would never think about the battens again. My thinking was to relief the tension on the battens so the joins would not be under load and they would be flat roller up in sail not bent, hoping this would prolong the life of the battens.
How many of you guys have experienced broken battens and is it a regular occurrence. Interesting point as i was researching battens and supplies, there was not supplier in Sydney that sell carbon battens only fiberglass in small diameter applications..
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.
I have an old batten with a large wood screw glued into the end . ( ground the head off ) .
Slide the batten down the pocket , twist it into the broken batten and pull it out , simples 
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.
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
Select to expand quoteDarrylG 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
DarrylG, This is what i would say is innovative its all in the design. simple tech for a quick result. I appreciate that Severne have included this in there sails it complements a great product and creates confidence as a buyer wanting innovation.
So having seen this would innovation tweaks in a sail persuade you in buying that brand or are we fixed to a brand irrespective what it does not offer, or is there not much more sail brands can offer.
I am aware duotone offer the ability to change the pressure on the cams with allen keys protruding the cam forward or back to suit the best rotation?, there could be a possibility to combine as many tweaks to create a super sail maybe anyway a bit of out load thinking.
What would you like to see in a sail.
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.
One innovative idea my sail brand has is putting shrink tube over the tip ends of the battens. If they snap near the cams, you can usually withdraw the batten with the broken tip attached by the plastic.
A friend has taken this to it's logical extreme and just shrink wrapped all his battens end to end! 
Been thinking of doing some of mine that way.
I couldn't watch it, that drill standing on the sail waiting to fall over and make a hole in it was to much
Hi Sandman1221 yep that is a point to try next time, try every thing else first before the drill make an appearance.
sailquik, i think that the heat wrap is smart it sure would resist in snapping and still have the smooth coating over the frayed batten ends easier to slid out. will try over one batten as see how it wraps, thanks for that.
Ben1973, my intension was not to make a suspense thriller the anticipation is nail biting,
I can see what your saying I'll replace the drill with a glass of beer.
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.
