Kitesurfing MacGyver control bar

Switch Controller 2

I recently purchased 4 new Switch Element 3's. These are great kites. I am very happy with them. The control bar is OK, but I have a few small issues with it that I wanted to fix.

So, bring on the Mac Gyver Switch / Flysurfer control bar....

My biggest issue with the Switch bar is the huge quick release. I don't have a big reach and I also use a seat harness with Dynabar, so I want the bar to be as close to me as possible. Here is a comparison of the Switch quick release next to the Flysurfer quick release:

Switch vs Flysurfer quick release

Other issues were:

• The swivel above the trim does not always untwist. And if it does, you still have a twisted 5th line. I prefer to loop both ways to avoid this. So the swivel can go.
• I had a pull pull trim on my last kites (Flexifoil), which I liked, but I was willing to give the cleat a go. What I did want though was smooth action. So the pulley had to be replaced with a good one.
• I don't like how much friction there is to pull through the front line when you release. So I decided to start with a mini 5th double front line safety setup and then move to a longer 5th if needed.

Here is a mockup of what was in my head:

Switch Mac Gyver Control Bar V01 Mockup

The swivel / pulley was replaced by a Ronstan 30 pulley:
http://www.ronstan.com/marine/product.asp?ProdNo=RF35101

The quick release was replaced by a Flysurfer. The 5th line was replaced by a thinner line so that it fits through the Flysurfer quick release, which has a thinner ID on the shaft than the Switch quick release. Here is what it looked like:

Switch Mac Gyver Control Bar V01

For the end of the 5th line I made a Brummel splice:
http://www.animatedknots.com/brummel/index.php?Categ=splicing

5th Line Connection Ring And Brummel Splice

I used a 2.5 mm line so that it would fit through the Flysurfer quick release.

Flysurfer quick release

For the pulley, I made a short length of 5mm Dyneema with a Brummel spliced loop at both ends. I then threaded it around the pulley and through itself twice before connecting it to the lines. This way if one line snaps, it cant thread itself through. The 5th line is also looped onto this small length of Dyneema.

Pulley connection

Pulley connection

I rode this setup for a month or so. I was really happy with it. The pulley was nice and smooth. The quick release great. The whole setup was really slick and simple.

However, the length of the mini 5th line was playing in the back of my mind. Also the fact that it is double front line safety. This means you don't loose all the power. So, I did a few tests with a 7m kite, and it worked OK. Kite stalled and dropped to the water, but it still pulled fairly hard. I tried it on an 11m and it pulled even harder. I used to ride a mini 5th line with double front line on my Flexifoils, but it was much longer than this and it allowed the kite to flag out more. So, I decided that this was not safe enough and I had to make it longer.

After much back and fourth, considering various pull through options, I decided to run a 5th line all the way from the bar, to half way up one of the front lines. Its a little more line drag, but its just so simple, and very unlikely to go wrong. There is nothing that has to pass through a small restrictions. Its all really simple and slick. At the top of the 5th line, I did a splice right into the front line. I have to say I was a little nervous about doing this, but I am keeping an eye on it and it seems to be OK. In theory it should not weaken the line much at all.

5th line spliced to front line

I put a ring at the pulley so that the 5th line could easily pass through it.

Pulley with ring for 5th line

And here is the final result.

Switch Mac Gyver Control Bar V02

Sure enough, the day after I added the long 5th line, I got totally munched in the surf and had to pull it. I was so glad I made the change. The waves were breaking onto the kite, but because it was only on one line, it was all good. I remember getting munched on the Flexifloil when on the mini 5th, it would almost rip the kite in two.

So I'm really happy with my new bar. The only thing left that is slightly annoying is the dangling end of the trim when you are de-powered.There is a clip, but its rubbish. I will post again if I come across a neat solution....