Kite Making Prep Sheet

see also free plans for non-commercial use

I’m duplicating this prep sheet for an amateur team in Suffolk, and also considering building my first kite.

Searching for Open Source kite plans went well,
Now to collect the tools and materials..

Thanks to Johnny for printing out the plans in A0 for me! Received them this afternoon (Tues 6th december 2016).

http://www.planprinting24.co.uk
Printing £12 (folded in the post, maybe rolled would support best accuracy where any small mistake changes the proportion of the build).

http://www.kareloh.com/kite-plans/2175-2/sixth-sense-plan/
sixthsense-plans

Choose Colours;
http://www.kareloh.com/6SCol/6Scolorizer.htm

Also I found this post on the fractured axel community about using water to hold the parts together for sewing, how fabric is cut, and the dangers of ‘build creep!’

honchoboy on the Fracturedaxel forum says he now uses a digital printer that specifically caters for plan printing for engineers, architects etc and so insuring that 10mm prints as 10mm.

I found a Sewing machine at a charity shop for £30, zigzag and straight stitches seem to work on rip-stop polyester, although the tension parts on the machine are a bit worn and not sure if it will handle my high strength thick polyester thread. Anyway I can get help with using one of the machines at Arts Network Lewisham.

 


See also My Kites: Spares and Repair

 

The following shopping list is based on work at www.kareloh.com
http://www.kareloh.com/kite-plans/2175-2/sixth-sense-plan/sixth-sense-std-pro-shopping-list/

http://www.kareloh.com/kite-plans/2175-2/sixth-sense-other-versions/

Tools:

I have included here a hot Cutter as used in a youtube timelapse video of the sixthsense being made. It has replacement blades available  €108,90 including tax. I have read that a very sharp knife and probably scissors will work on icarex fabric which does not fray, although it does if I pull at the edges.

Glue plastic and carbon fibre (superglue)
A water based glue for the kite fabric (or use just water for a temporary hold).

Retailers and their estimated Shipping costs:
I have come accross some issues in shipping from the USA, so am comparing the nearest and cheapest suppliers.

Estimated Cost of Build in Pounds per eight kites including VAT:
SAIL: £289.33 or £36.12 per kite + a water-based glue if needed
BITS PRO: £249.97 or £ 31.25 per kite
BITS BASIC: £175.36 or £21.92 per kite
FRAME PRO: £827 or £103.4 per kite
FRAME BASIC: £373.14 or £46.64 per kite

TOTAL PRO: £170.77 per kite before shipping
TOTAL BASIC £104.68 per kite before shipping

Estimated Shipping Cost in Pounds:

metropolis-drachen; up to €125.79 €13,90 /more than €150,00 €8,90 /more than €250,00 €3,90

bilboquetsport shipping €14 offered for any order of €100 or more, large order free shipping

kitehouse shipping €15,00

benson postage £2.50

levelOne shipping by arrangement email request sent
First I will run through the checklist for the STD Pro frame. Secondly I will cost the STD Basic frame and the connectors;

STD Basic

Sail: Icarex, mylar, dacron.
Leading edge: Structil 6mm
Upper spreader: Structil 6mm
Lower spreader: P300
Spine: Structil 6mm
Stand Off: 3mm carbon
Ballast on tail: 25g

STD Competition

Sail: Icarex, mylar, dacron.
Upper leading edge: P200
Lower leading edge: P300
Upper spreader: Structil 6mm
Lower spreader: 5pt
Spine: P200
Stand Off: 3mm carbon
Ballast on tail: 25g

STD Pro

Upper leading edge: Black Diamond Nitro 71,5 cm
Lower leading edge: Black Diamond Nitro Strong 82, 5 cm
Upper spreader: Structil 6mm 54,5 cm
Lower spreader: Black Diamond Nitro 78,1 cm
Spine: 5pt (101cm) 91 cm
Inner Stand Off: 3mm carbon 28,5 cm (without connectors)
Outer Stand Off: 3mm carbon 27,5 cm (without connectors)
Ballast on tail: 25g

Sail material: Initial quantities are per kite

Icarex by colour per meter

1,5 m Icarex PC31: http://www.thehighwaymen.co.uk/PBSCCatalog.asp?ItmID=9916113 18.99 GBP p.m

bilboquetsport  €16,90 p.m  1.5 meters per kite. Choose colours for each kite and buy to scale. Total 12 meters €162,80

15 cm Bisonyl (LKW plane) 10 cm wide or Cordura
metropolis-drachen
Cordura €11,90 per meter x W148cm. This would cover 8+ new kites

50 cm Mylar full width from roll
bilboquetsport Mylar €28,00 p.m Price is for 100 cm by 138 cm width. Total €112.00 8 Kites
levelonekites Mylar €23,00 p.m. Quantity is for 10 cm by 140 cm width €2,30. Total 92,00 8 Kites

5 m Dacron tape black 5 cm wide
bilboquetsport €1,10 pm
or
metropolis-drachen€0,85 pm Total €34,00 8 Kites

4 m Spinnaker tape black 2,5 cm
metropolis-drachen €1,95 per 1 m x 5cm. Total €31,20 8 Kites

20 cm Velcro 3 cm wide
metropolis-drachen Total €4.80

metropolis-drachen Sewing thread 1800m €11,00


 

Bits and Pieces STD Pro:

4x APA Db Leading Edge Connector

: 7,5 (A) x 5,5 (B)mm 4x€1,60 Total €6,40 x 8 €51,20

 

4x APA 200 Standoff Connector
metropolis-drachen: 5 x 5,3mm Germany 4x€1,60 Total €6,40 x 8 €51,20

2x Exel Standoff Connector 7mm + tiewraps (Level One yoyo stoppers) or APA 200

Alternative to R Sky type yo yo stoppers on Fractured Axel Forum
Set of 10 x 6mm soft plastic available at R-sky
€11,00 Out of stock
kitehouse catalogue yoyo stopper Total €2,00 x 8 €16,00 + postage

1x R-Sky Center Cross: 6mm x 7mm(Spine x Ferrule diameter)
Total Center Cross 1,70
and related part; skyshark internal ferrule

1x Center Cross Benson 6x7mm not available
1x skyshark internal ferrule: R-Sky Total internal ferrule €1,80

1x Skyshark-crossjoint €4,50 x 8 €36,00
(see frame options, to make the ferrule a carbon tube 7mm o.d which is 0.5mm thick tube with solid carbon rod inside 6mm o.d. Ferrule length 108mm )

 

4x HQ Sailgrabber (with screw) or Jaco short with O-ring, 3 mm
levelonekites
Total Jaco short €0,60 x 4 €2,40 x8 €19,20 +postage
Screwable sailgrabber:
Total sailgrabber €2,80

 

3x FSD Splitnock 8 mm (1 spare)
metropolis-drachen Total Splitnock €2,85 x 8 €22.80

10x C-clip 7 mm:
metropolis-drachen Total C-clips €1,50 x8 €12.00

 

endcaps: 3x Vinyl Endcap 6 mm (nose)  / 4x Vinyl Endcap 3 mm (standoff)
metropolis-drachen
Total endcaps €0,39 + €0,36 = €0,75 x 8 €6.00

1x Weight 25 gr:
metropolis-drachen Total Weight €3,00 x 8 €24.00

1x End Cap for velcro spine end
metropolis-drachen Total End Cap €0,70 x 8 €5.60

10 m Bridle line 90 kg
bilboquetsport Total Bridle line €6,00 x 8 €48.00


Frame STD Pro:

http://www.kareloh.com/kite-plans/2175-2/sixth-sense-plan/ssdetails/

 

1x Structil 6 mm 82,5 cm x 8 £102.48
bilboquetsport Total €11.90 for 165cm (however a little close for comfort exactly 2x 82,5cm)
allproppedup 3 Meters £12.81. 9 meters Delivery £15 up to 15kg

1x Carbon rod 3 mm 150 cm 15 meters @ £27.00
allproppedup Total 5 Meters £9,00 Minimum order £25. Discounts for larger quantities
or
bilboquetsport Total per 100cm @ €4.10

 

Skyshark specs

1x Skyshark 5pt 101 cm x 8 €105.6
bilboquetsport Total 5pt €13,20

12+ from Goodwins $16.99 (£13.51)

4x Skyshark Black Diamond Nitro 82,5 cm x 8  €446.40
bilboquetsport €13,95 each. Total Black Diamond Nitro €55.80 inc vat

2x Skyshark Black Diamond Nitro Strong 82,5 cm x 8 €262.4
shop.levelonekites Total €32.80 + postage
or
bilboquetsport Total €33.90 x 8 €271.2

1x Skyshark Black Diamond Ferrule DONE

(see skyshark internal ferrule by R-sky above or make from scratch)
 Parts: Carbon Tube, Carbon Rod, Glue

2x Skyshark p100 10 cm

 


STD Basic

Sail: done
Leading edge: Structil 6mm
Upper spreader: Structil 6mm
Lower spreader: P300
Spine: Structil 6mm
Stand Off: done
Ballast: done

Upper leading edge:  71,5 cm
Lower leading edge:  82, 5 cm
Upper spreader:  54,5 cm
Lower spreader:  78,1 cm
Spine:  91 cm
Inner Stand Off:  28,5 cm (without connectors)
Outer Stand Off:  27,5 cm (without connectors)

Bits and Pieces STD Basic:

4x APA Leading Edge Connector
metropolis-drachen Total €6,40 6x6mm APA x 8 €51.20

4x APA Standoff Connector
metropolis-drachen Total €6,40 for p300 outer diameter 4 x 8 €51.20

Center Cross
metropolis-drachen Total €2,20 fibre reinforced crossjoint x 8 €17.60

2x Aluminium Ferrule Leading Edge
metropolis-drachen Total €4,40 inner diameter 6mm x 8 €35.20
4x Sailgrabber
levelonekites Total Jaco short €0,60 x 4 €2,40 X 8 €19.20
metropolis-drachen Total Jaco long €0,65 x4 €2,60

3x Splitnock (1 spare)
metropolis-drachen FSD hard tops €1,80 x 8 €14.4

10x C-clip
metropolis-drachen Total 10x6mm €1,50 x 8 €12.00

x3 6mm End Caps, x4 3mm End Caps
metropolis-drachen Total €0,75 4x3mm €0,36 3x6mm €0,39 x 8 €3.12

Tail End Piece 6mm
metropolis-drachen Total €0,70 x 8 €5.60

Frame STD Basic:

See Structil from all propped up for large order uk
Upper leading edge:  71,5 cm
Lower leading edge:  82, 5 cm
Upper spreader:  54,5 cm
Lower spreader:  78,1 cm
Spine:  91 cm

first 3 meters:
1x Structil 6mm  71.5cm,
2x Structil 6mm  82.5cm,
1x Structil 6mm 54.5cm remainder 9cm

second 3 meters:
1x Structil 6mm  71.5cm,1x Structil 6mm 91cm remainder 137.5cm

2x P300 78.1cm

Carbon Rod 3mm allproppedup Total 5 Meters

Total Structil = 382cm allproppedup 3M so buy 6M leaving Remaining 137.5cm for spares. Total £30.74 including VAT x 8 £245.92

bilboquetsport Total €11.90 for 165cm 6mm Structil 2x 82,5 cm
bilboquetsport Total P300 €19,00 2x Skyshark P300 x 8 €152.00


 

Kite line, sleeving, and handles

5 m Dyneema flying line (as leftover from a 100m spool)

For pair/team-flying we will need at least 40m; we fly with 45m lines, 5m of which are separate leader lines positioned on the kite side which break more often.

(we will need several sets of line for the project, 100m will cover 1 set, I have chosen 70kg line for moderate winds)
metropolis-drachen
Climax ProTec 70 daN €29,90

Winders:
Climax winder €2,40 metropolis-drachen

Sleeving/ Sleeving Kit:
you can use 1,5 or 2mm sleeeving for the 70 daN Protec line. The 1,5 is a little bit tighter, the 2mm goes a little bit easier on the line.

metropolis-drachen Sleeving €0,35 per meter
bilboquetsport Sleeving €0,50 per meter
metropolis-drachen Sleeving Tool, Splice Needle €1,00

Handles:

bensonkites Benson Straps £12.50
bilboquetsport pair of wrist straps for stunt kite €4,50
metropolis-drachen eliot straps €4,90

Extras

Those breaks I was meaning to get to overcome stronger wind:
r-sky -€18,00

bilboquetsport19,90

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