Scott,
I have an archived email discussion between the previous owner of my boat and Dave Cross at Quantum regarding a large roach main in my file cabinet downstairs. In the end the previous owner stayed with OD specs and bought from North... though I seem to remember him saying that he regretted not "turbo-ing" the main later. If I remember correctly Dave also suggested a smaller headsail as part of the formula (maybe 155?) to ease the rating hit. I'll see if I can dig up his old recommendations. Dave certainly makes fast sails and tends to know what he's talking about so I'd think about it carefully.
The rating hit seems significant as I am now rated 142 with old sails credit and my 163 headsail, and this after a base rating adjustment this year (maybe that Viking 33 that I beat by 1 sec corrected last summer took offence and appealed). A two boat testing programme sounds like fun though. How about main sails only next time you're in town?
BTW Scott, Wednesday night racing starts on the 21st. Let me know if you are in town one of these weeks and I'll try and find a crew spot for you.