For this Barn-Door, you need long lengths of 5mm (3/16") wooden dowel.
It is easily cut to the lengths required with a small cheap hack-saw.
Note: The length of bought dowel can be somewhat inaccurate. So if you have bought 2.4 meter lengths of dowel, you might have a couple of centimeters less than you bargained for! Hence I cut my 120cm spars from 1.8 meter lengths of dowel.
- Lay down dowel diagonally over the sail, cutting off a length that goes from the top-left corner to the bottom-right corner. This is one diagonal spar.
- Do the same for the other diagonal spar which goes from top-right to bottom-left.
- Lay down dowel horizontally over the sail, and cut it to length so it goes from the left-most corner to the right-most corner. Mark this dowel with an 'H' since it is your horizontal spar.
- Cut off a very short 0.01DL (1.2cm, 1/2") length of dowel. This will be used as the bow-line toggle.
- Using your wood file, round off the tips of every piece of dowel you cut off.
Now there's a little work to be done on the horizontal spar. Use 20 pound flying line if you have some, otherwise just use some of your 50 pound flying line. With this kite laying on the floor, each tip of the horizontal spar will be 0.08DL (9.6cm, 3 3/4") above the floor.
The remaining steps...
- Make a hole in the plastic right where the spars cross.
- Wrap each loose end of line around the crossed spars - twice. The loose ends should go around in opposite directions. See the top photo.
- Pull the lines tight. Tie them off tightly against the dowel, right near the hole in the plastic. A Granny knot is fine.
- Pull the 2 loose ends together, and tie them into a Simple knot near the end of the line. See the middle photo, where the line has also been fed through the hole in the sail.
After the bridle has been made up, one line connects to where the spars cross, with a Lark's Head knot. This is shown in close-up, in the bottom photo.