A box from the man in brown.
The good stuff inside the box.
Diffusion WK100v1 Parafoil colors.
Getting the angle to cut the internal rib sections. Light blue first.
First section of color for the rib cut. White rib just for sizing.
Cutting the second color section.
Cutting the third color section - 24" wide.
Color sections laid out - white rib on top.
Color sections laid out. White rib on top.
Lining up the color sections for the rib to be sewn.
Three color sections put together with sacrificial double sided tape. Some idea of the hoped for color blending.
Rib color sections being joined.
Straight stitch joins 2 panels with a 1/2" seam. Then hot cut 1/4" off of that.
Color sections joined - awaiting cutting to final rib shape.
Completed rib color section joint seam. Straight stitch joining panels. Hot cut to joined panels. Remaining 1/4" hot cut seam allowance folded over and zig-zag stitched down.
Marking the 1/2" seam line with brass measuring block and straight edge.
Marked seam allowance - joined with DS tape.
Corner overlap for straight edge when folded out flat after sewing seam.
Panels assembled for sewing seams.
After straight stitch, hot cutting seam allowance to 1/4".
Zig-zag stitch to finish seam
Color stack of panels for rib - progressively smaller to minimize waste.
Leading edge of rib - cut from template.
Leading edge and color rib panels joined to one length.
Marking rib shape from original template.
Trailing view - marking rib shape from original template.
Pile of ribs.
Outside rib and assembled but uncut inner rib.
Uncut inner rib with outside rib underneath for marking.
Template for rib venting
Template for rib venting under glass (larger rib vent template for 525 beneath it).
Detail of rib venting template
Rib venting template as seen through rib fabric.
Hot cutting ripstop and DS tape for rib venting reinforcements.
Reinforcement strips cut out. Matching colors to limit the exterior visibility.
Cutting ribs to shape.
TIP - keep the hot cutter far away when not in use.
Cutting ribs to size.
DS tape on matching ripstop to create reinforcement strips for rib venting slits.
Sewing reinforcement strip with 3 step zig-zag stitch.
Reinforcement strip detail passing over panel seam.
Reinforcements in place over venting template. Ready for hot cutting the venting slits - aka gills.
Hot cut from one hole to the other with straight edge over template.
Completed rib venting and reinforcement.
Add low stick painters tape to keep vents in place to prevent catching during the rest of the sewing.
Hot cut hole at end of each vent line - barely hot cut into reinforcement to form fused end.
Adding reinforcement sticky back dacron to corners of keels. This is the less than 90 deg angle where the bridle line will attach. Place dacron on both sides of the keels.
3-step Zig-zag stitch to hold curved edge of keel reinforcement. No need to sew straight edges - they will be covered and sewn with the binding.
Completed keel reinforcements - both sides of keel.
Keel reinforcement detail.
1" binding attachment. Friends don't let friends do binding without one of these.
Binding applied to leading edge of outside rib.
Binding being attached to leading edge of inside rib.
Detail on edge binding for leading edge of inside rib. Keep the fabric fed in tight to the binding attachment so it is seated all the way into the binding fold.
Binding on keel from trailing edge forward. Stop 1/2" from leading edge of reinforcement. Measure out enough binding for leading edge and cut binding from roll. Pull binding out of attachment.
Hot cut 1/2" slit in middle of binding. Front of slit is at leading edge. This is just wide enough to feed binding - folded to go around leading edge - back through the slit.
Feed binding through slit and along leading edge. Pull most of binding through slit. Leave loop for bridle line attachment.
Reverse view - feeding binding through hot cut slit and along leading edge of keel.
Here is the loop for the bridle line attachment. Binding will be sewn on leading edge of keel. But first feed binding back into binding attachment - backwards - feed it through the narrow finished edge. This is a PITA - use tweezers.
Detail - feeding the binding into the attachment backwards.
Success - binding is back in the attachment backwards. Pull all the binding through until tight against sewn part.
Binding pulled back through attachment. Positioning needled to sew leading edge of binding on keel. Leaving sufficient loop for bridle line attachment.
Sewing binding up leading edge of keel just the same as always. Leaving integral bridle line attachment loop at corner.
Added power stitch across tip. Completed integral bridle line loop as part of edge binding. This method spreads the bridle line attachment point stress along the entire length of the binding.
Detail - stopped (and backstitched) 1/2" from leading edge.
Starting at trailing edge of bottom of keel - sewing second binding stitch. Have already sewn around bridle line loop 1x to create flat folded triangular shape. Will sew second pass as part of the second stitch all the way around the binding.
Stack of completed keels.
Completed stack of keels.
Completed stack of ribs.
Adding binding to leading edges of top and bottom skins. Chain stitching for ease of handling.
Completed stack of leading edge bound bottom skins.
First assembly seam. Outside rib. Keel. Bottom face skin. Power stitch on binding stack to reinforce that stressed joint. Used excess binding as a handle to move the stack through the machine. Hot cut excess binding after finishing the long seam.
Stepping down after sewing the binding. Now for the long 10' seam. Outside Rib - Keel - Bottom skin.
After sewing first pass of long seam. Open up seam with rib laid out flat. Sew excess seam allowance to rib face. Make sure it is flat and does not catch any other part of kite.
Looking back at the second long seam.
Second long seam lined up on table for ease of feeding into the sewing machine. Bottom skin (the open edge from the seam just sewn) - Keel - Bottom skin - Inside Rib.