Andrew:
Hello fellow Triangle sailor! My opinion, personally I wouldn't worry too much about any difficulties in cleating down your sheets (engaging them, seating them, whatever you want to call it). What's important is ease of RELEASING the sheets out of the cam cleats, as in before you capsize or have to round up. Which is why GL skips on the fairleads, one less thing to foul. Of course, it helps that he uses ratchet blocks, I copied his idea and love it. Likewise, tie the end of your jib sheets together. As for the jib sheet cams, you can always engage them using your feet, at least for "normal" double cams, dunno for your single-sided cam. Anyway, look at this post, GL is spot on (and apologies for my boosterism) :
viewtopic.php?f=12&t=5831#p34619If you insist on tufnol, you can get them from several vendors here in the US, they're made by Hye in Germany. Google tufnol cleats or phenolic cleats (tufnol is the UK brand name for phenolic resin/cotton laminate, "Micarta" in the US).
BTW, if you're not keeping the single-side cams, I'd love to buy or trade for them. I'm slowly rigging a spinnaker setup, these would be great for the sheet/guys. If you ARE keeping them, you can probably refurb them with a file as GL suggests and maybe new springs. Did you try simply tightening them?
Cheers and see you on Jordan Lake!
Tom