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:
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...
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...
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.
Yeah on my older Sunfish I had made a little wooden mount at the tiller. I later switched to mounting it upside down out on the lower boom.
https://my2fish.wordpress.com/2012/06/27/gopro-camera-pov-on-a-sunfish-sailboat/
I think 2-yrs old was probably the youngest I actually sailed with one of my boys.
In this video at about 2 minutes in you can see me grab my 2-yr old from my wife in a kayak. My 5-yr old was already with me.
It was a VERY calm drifting day on Lake Michigan and she stayed nearby in the kayak.
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