Love that technical talk
That was cool to read!! For sure, if the sail is built to max phrf girths, it will overlap the backstay, and almost as surely, Ted's new main is not quite maxed out. I am 99% that the max girth percentages of E are nearly the same everywhere-certainly not significantly different. The were originally the IOR max girths.., and in any case with a sail with such a high aspec ratio, it would overlap the BS if FULL FULL size.
This is not a problem at all in terms of chafe (despite the fears of many), and only in very light air does it hang up during a tack or gybe.
One would assume that anyone ordering a max girth main also has a hydraulic BS-the point being that in these conditions, if it does hang up, you will have the BS so loose that you can usually just give the BS a firm shake and the leech will pop through. It is at most a minor inconvenience, and IMHO, more than offset by the sail area gains.
Having said all that, the 38 is powerful enough that unless I was in a mostly light air region (Ted), I might back off just a bit on the girths, since for upwind sailing the advantage goes away by the time you have about 10 knots of wind-more breeze downwind before the edge goes away, but you get the point-the 38 carries a lot of sail. In light air though, the max sail will be noticeably faster and higher.
Ka Ching!
S