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.

The finished product, bundled and ready for installation on a kite

Figure 1.1: The finished product, bundled and ready for installation on a kite

1.1 Bill of materials

  • 1 kite control bar: 17" - 20" between the steering lines; a rimless, circular trimline borehole on the kite-side of the bar; a deeply beveled cut left and right of the trimline borehole on the pilot-side of the bar.
  • 2510mm Samson AmSteel-Blue Single Braid Line Diameter: 5/32" (4mm)
  • 4910mm Ultrex 12 1/16"
  • 310mm Samson Ropes Amsteel Blue AS78 Line: 7/64" (2.5mm)
  • 1 Small Stopper Ball Green ~5/32" ID, 16-18mm OD
  • 1 Medium Stopper Ball Green ~1/4" ID, 25-32mm OD
  • 1 Separation Block v2 6mm trimline bore release 1.4.2
  • 1 Cleat Bead release 1.4.2
  • 1 Chickenloop Handle
  • 55mm x 55mm square of 0.025" thick 430 stainless steel sheet.
  • Two 2" long, 1/8" cotter pin
  • 40mm of 1/2" OD vinyl tubing
  • ~260mm of 2mm bungee
  • 3/8" diameter bead or 1/2" of 1/2" vinyl tubing
  • ~39mm of 0.102" Diameter 304 Stainless Steel hardened wire

1.2 Tools required

  • Razor blade or other very sharp knife
  • Cutting board
  • 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
  • 2m long stick and some scrap line to place the flag line under tension
  • Adjustable wrench for line stretching
  • 5/32" drill bit
  • 1/16" drill bit