I installed an 6 inch SS painter between the lower furler and the sail tack, I replaced the upper furler halyard attachment with a longer shackle. Both of those seem to have combined to give me good clearance... and the halyard no longer wraps around the furler foil.

I have tested this several times... but only in winds up to about 10 knots. It has worked without fail, thus far.

I think moving the sail up just those 6 inches changed the angle of attack for the halyard to the furler... adding the longer shackle no doubt gave the foil something less to rub against to start the wrap.

Gonna just sail it and see if it decides to fail... worst case, I have to take the jib down at the bow in snotty weather because it won't furl.