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Old 05-21-2011
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From the photo, it looks like the snap shackle on the jib halyard is hitting the forestay. THAT may be your problem. Added to that, the too-long luff you mentioned on your jib means the whole thing isn't pulled tight, so it slops around more than it might otherwise, enabling the stay and the shackle bang against each other on every single wave you hit, or that hits you. That, plus the shock loading of the snap shackle, as the mast whips back and forth. Bang on anything long enough, and it will break. You might want to carefully inspect your forestay around where the shackle's been hitting it too. The spinnaker crane seems to have been designed for a totally external spinnaker halyard. If you simply led the two ends down to the sides of the mast, the block would swivel to be at right angles to the forestay, and the spinnaker halyard(s)might not even touch the forestay or r/f gear. Rigging the spinnaker halyard so that it chafes on the r/f or forestay, as the photo shows, is not a good idea: you mentioned that it has also chafed through. Running it inside the mast to reduce windage seems pointless with such a telephone pole-like spar. Good luck!
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