I blew up a while back saying Vibram was a bad company because I never got an e-mail response after my KSOs tore. I called them a few days later after my angry post and they had a replacement pair of KSOs out to me in less than a week. I tore those too, in the same EXACT spot. I called Vibram and asked them what I should do, they said some people put stress in odd areas on their feet and said I should reinforce it, or bring it to a licensed Vibram dealer and they'd repair it and reinforce for me. I said I could probably manage myself and set to work on my beloved battle armor.
I looped some black thread back on itself to double the strand, then tied a few hearty knots and set to work repairing the damaged spot. I made close tight passes slightly under the original thread zone. More fabric to grab onto means the area can handle more stress when stress is acted upon the area, after one pass I tied it off at the end then went back over it with 1/2 the loops, tied it back through the starting point and ran a lighter over the area to tighten/fuse the threads.
I have yet to test my repaired battle armor out, but here is my handy work. It's ugly as hell, but it looks strong to me!