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Author Topic: replace my broken FW Insync lower leading edge  (Read 2169 times)
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Location: Seattle, Washington

« on: November 03, 2010, 08:29 PM »

The spec indicates the frame/leading edge as 6mm carbon tube.  6mm is 0.236" while there are only 0.230" and 0.240" carbon tubes avaiable.  Which one should I use?  In addition, the portion of the tube near the leading edge ferrule is plugged with reinforcing.  What should I use for reinforcing?  Another solid carbon inside?  If so, what should be the diameter of the reinforcing rod and how long?
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Location: Lincolnshire, UK

« Reply #1 on: November 04, 2010, 03:15 AM »

I'm not sure where you are, but 6mm is fairly standard size for carbon tube.  Of the 2 sizes you quote I would go for .240 if you cannot get proper 6mm.  This may be very slightly big, so you may need to make the hole in the centre 'T' a little bigger but try it first. The re-enforcing plugs are usually made from solid carbon rod - about 2 to 3 inches long. Depending on your carbon tube you will need either 3mm (0.118") or 4mm (0.157") carbon rod which is superglued in. Good makes of 6mm carbon tube include Exel Cruise and Structil but it depends what is available in your area.

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Lee S
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« Reply #2 on: November 04, 2010, 11:30 PM »

Going in the opposite direction it would appear, when replacing a 6mm rod with a decimal rod, I've always used the .230  For example, 6 thousandths is very tiny small amount of difference, so small that a single wrap of Scotch tape will make your rod too big for the ferrule. By comparison, it's somewhat harder (at least for me) to accurately sand off exactly 4 thousandths (maybe 5 for good measure) and I've always felt that removing the outer coating off a rod made it that much more likely to break or wear out. You could always coat a 230 rod in some fine powder Cheesy  (no, actually baking soda comes to mind. What were you thinking?) which should take up the extra space.  If you're worried about fine tuning, then you might want to replace broken spars in sets, so maybe both lower spreaders.  Honestly, I wouldn't worry about it myself, except in the case of lower spreaders, where different flex might be bothersome. Most of my old English kites are repaired with decimal spars, and I've noticed no difference in performance at all. If internal reinforcement is desired, I'd just use what you can find. If you don't have a ready supply of small gauge carbon or fiberglass around, I've used bamboo with success . Just saturate it well in CA glue, then be really fast in shoving it in, and trim off the excess.


« Last Edit: November 04, 2010, 11:33 PM by Lee S » Logged
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Location: Seattle, Washington

« Reply #3 on: November 04, 2010, 11:47 PM »

Thank you both for your help.  I will try 0.230" tube first with whatever solid rod reinforcing that I can find in our local kite store in Seattle.
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