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i just sent in a pair of Chaco Z-1s to get re-webbed. this pair has seen a lot of sand and grit, and the webbing was frayed near where it enters the footbed. that probably has something to do with the sand that inevitably works its way under the footbed. Chacos adjust by sliding the webbing beneath the midsole, and sand tends to collect in that space. the webbing has gotten somewhat stiffer and less forgiving from repeated soaking and drying, and the webbing they were using 4 years ago was always somewhat harder than the newer ones.
i figure that the re-webbing process will require them to remove the sole from the midsole, which will take care of the accumulated sand that i couldn't completely deal with despite cleaning, soaking, and moving the straps around. it will also be interesting to see whether they make any observations about the sole. it is in pretty good shape, a "diamond stealth" sticky rubber sole that is great on wet rocks, not so great if you care about leaving black marks on flooring occasionally. Chaco hasn't offered the 'diamond stealth' sole for a while, and i personally think the rubber is better on wet rocks than the current 'pro' sole.
one reason i chose to repair rather than replace is that apart from the frayed edges on the webbing, the midsole, sole, and hardwear is in pretty good shape. another is that Chaco no longer sells the Z-1 or Z-2 pro in wide, which I need; to get a wide chaco with a water-friendly sticky sole today, you need to order them as a custom pair ($125 bucks). a third reason is my bias toward the older sticky sole, rather than the newer 'pro' sole. finally, the new webbing will definitely be softer than what i'm replacing, which my feet will appreciate.
stay tuned, and i will update on the process.