Chapter 1 Overview

This document describes how to build a Buggy Bar. The Buggy Bar is a kite control bar designed by and for Kite Buggiers. This bar is targeted specifically at non-jumping land-kiting with a focus on high function and ease of use to keep the flier safe and focused on piloting. This design is released under a Creative Commons license to allow anyone to use the design to build the bar for personal use or resale.

1.1 Bill of materials

  • 2430mm Samson AmSteel-Blue Single Braid Line Diameter: 5/32" (4mm)
  • 4910mm Ultrex 12 1/16"
  • 400mm Samson Ropes Amsteel Blue AS78 Line: 1/8" (3mm)
  • 1 FR5 Tylaska Rigging Ring Ferrule
  • 1 Small Stopper Ball Blue 5/32" ID R1905
  • 2 Medium Stopper Ball Green 1/4" ID R1994
  • 1 Separation Block release 1.4.2
  • 1 Cleat Bead release 1.4.2
  • 55mm x 55mm square of 0.025" thick 430 stainless steel sheet.
  • One 2" long, 1/8" cotter pin
  • 40mm of 1/2" OD vinyl tubing
  • ~120mm of 2mm bungee
  • End of the handle from a plastic bucket

1.2 Tools required

  • Razor blade or other very sharp knife
  • Cutting board
  • Lighter or propane torch
  • Scissors
  • Short wire fid (~150mm)
  • Long wire fid (~850mm)
  • Cyanoacrylate glue (preferrable thin)
  • Cyanoacrylate accelerant (optional)
  • Metric tape measure
  • Sewing machine with a large needle and high-strength polyester thread, preferably V-46 Dabond 2000 UVR Polyester thread
  • A modified presser foot with a 1mm-wide groove aligned with the needle.
  • Rubber mallet
  • Bench vise with wooden jaws or other means of bending 0.025 metal sheet
  • Two strong spring clips
  • 2mm long stick and some scrap line to place the flag line under tension
  • Adjustable wrench for line stretching
  • 5/32" drill bit