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If the failure is at the sewn seam (circumferential), why not change the sewing to radial lines from the attachment point? It might cause the tie-out to tear into strips, but this might at least have some strength.
You might have to finish the edges of the sewn-on patch first to stop it fraying.
I'm also wondering about how realistic the test is when the rest of the sheet isn't tensioned (as it would be in a more realistic application, e.g. tent or tarp tie-out). It may well be that the puckering that occurs causes stress concentrations along the seam that wouldn't occur with a 'normally' set up tie-out.
BTW, good work as always, Daryl.
Edited by captain_paranoia on 01/05/2012 11:56:47 MST.
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