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I discovered the outer windings in the line that unfurls the furler has developed a nick (mid way on the deck) that has caused it to unravel itself. Thank goodness there is a separate single core line embedded within to keep the line from flat out breaking in two.

Is there any trick that I should know when replacing this? Is it known how much I'll need in terms of footage and any other line specs? Where is the best place to purchase the replacement line? Any info appreciated.

It's pretty easy. Take a chunk of the broken line down to a marine store and tell that you need so many feet. You have measured the amount you have lost, so you know what to tell them.

When you line up your drum the next time, you have options I hope you understand, make sure it doesn't chafe against the drum. No one has had problems with it except you.

Your Flexible Furler Installation/Operating Instructions recommends:

Furling Line 5/32” or 3/16” braid on braid dacron. If you prefer a larger diameter, you should decore the portion of line forward in the cockpit.(Otherwise the larger line won’t fit onto the furling drum.)

You MAY find even with 3/16" you need to decore the end that winds on the drum.

As Sloop notes, you don't have to mount the cup with the hole facing straight back. You can put it at an angle to prevent chafe. Note the alternative screw locations underneath the cup for installing it at 45º to prevent chafe.

What does "decoring" mean?

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You can just get the 150 genny on the CDI FF2 furler with 3/16 inch furler line with a decently tight wrap if you start with 5 turns of line on the furler drum Ive found. More than this and you run out of furler space, less and you run the risk of not being to get that last few feet in. I have found the line is rubbing in the drum and sometimes the sail wont deploy, but the first good puff fixes that....WWWWRRRRRMMMMPPPPP!!!!