Liftjacket test and ZIP

Option (1) was definitely better than option (2) then.
Reasonably good customer service too; much better than some.
And you have not thrown away a serviceable piece of kit (subject to your twice a year tests). Kudos.

My spinlock has the 'funny' zip and I had to use youtube to help me re-pack it (I leave all my life jackets 90 per cent inflated over winter so creases Don't become weak points). I also have to video the unpack to remind me how to repack.

The spinlock is tightly packed, so you may be able to add some mm of space when you sew the new zip on.

Have a good trip.
 
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The zip slider should be right at the end of its run and, like a jacket zip will come apart. About 9" further along the zip, locking teeth are missing for about 2" which allows the zip to burst open along its length on inflation and the end of the zip pulls out of the slider. I suspect the OP's zip slider was not at the end when inflated.
Yes, that's what I remember. I suspect you are right - his slider was still engaged and not at the end.
 

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