Chatter, chatter
Well, guys-
I first saw this phemon when working for Q, and it seems to happen mostly with composite sails or those made from really stiff dacron. It is partly a function of car spacing-except that the normal rules for spacing were adhered to and it still happens-so it is very hard to predict when this will result...as weird as that sounds it is true.
There are 2 solutions. One is to increase cars (reduce spacing), but this has its' own problems- namely weight, and the increase in stacked car height when reefed or stowed.
The best solution, and one I'm sure your sailmaker will go for (since it is a one-time cure and costs less than a bunch of cars), it install a "luff line", or leech line for the luff. It may need a small purchase to get enough tension, but this is a legitimate fix-most big boat mains-especially composite sails with facny car systems (batcars, etc) have them as standard, and let's face it boys, you guys with the 38's are "right there" as big boat owners!
The smaller the boat the less this seems to happen, but not unheard of these days with fancy mast cars and composite sails.
It is elusive and not consistent-which is why the luff lne is often not fitted until you get into bigger sails-but I have seen it on Farr 395 mains, C&C 38's, Beneteau 42's etc.
Run this by your "industry professional", as let us know how it goes!
Seth