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Malay Building InstructionsMaterial needed (you can use other size spars, I happened to have J65s

on hand):

Ripstop 2 yardsJ65 x 4 Fiberglass Hallow Spars, 32 1/2 long

1 - J65 internal connector (I used 4 piece of RET 30 from the Kite Studio)

1 Dihedral, bent 300 in centerto fit J65 Spar

4 Vinyl end caps for J 65 Spar, Vinyl End Cap - .312", 5/16

125# Dacron Line 85 inches for Bridle

Fabric for Reinforcement

Aluminum Rings 3 needed

Bridle/Tail Fabric for Holders 1X 30

8 x 70 fabric for bag.

Fabric Cutting (All measurements are in inches):1) Cut out and mark 2 pieces as per sail pattern, reversing 1 making sure to add seam

allowance on all 3 sides, drawing #1.

2) Cut out the 2 each of the top, bottom and side reinforcements, reversing 1 each. Drawing#2.

Grain

Cut 2 reversing 1Add1

inch

seam

allow

ance

Add1in

chseamallowance

Add 1 1/8 inch seam allowance

Bridle pointBridle point

63

19 3/4 9 1/2

33

1/4

Drawing # 1

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3) Cut out 4 each of the bridle reinforcement, reversing 2. Drawing #2.

4) Cut out and mark the bridle, use 125# Dacron Line. Drawing #3

Construction:Preparing of Tail and Aluminum Ring Holder:

1) Fold in half lengthwise

Side Reinforcement

Bot t om Reinfor cem ent

Bridle Reinforment4 needed

Foldlin

e

2 n e e d e d2 n e e d e d

Top Reinforment

2 n e e d e d

3 1 /2 1 /2 1/2

31/2

4 1 /2

41/2

2

2

2

1/2

13/4

147.8

Drawing # 2

1 1 /2

23/4

1

2

1

/4

1

1

1

2

1

/4

1

/

2

4 42

1

/4

3 3 /86 3 /4

Bridle

32 3/4 47

Top Bottom

5 5

Knot Knot

Drawing # 3

89 3/4

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2) Fold in half lengthwise again put cut edges into center3) Sew along in the center lengthwise, no need to sew 1stand last inch. I found out the

sewing machine tries to eat it otherwise

4) Cut sewn part into 3 pieces, 3 long, 31/2 long and 165) Fold each in half widthwise, example: 16 finished length is 8

Mail Sail:

1) Mount and sew all reinforcements where indicated other that the side reinforcementson the back side of sail. Drawing 4.

2) Double fold each of the outer edges ofthe sails forming a edge around theedge on the back side. Do this for both

trimming excess at corners. Drawing 4.

3) Fold side reinforcement in half. Alignfolded half with corner where spreader

will go, sew the part on the interior of

9 9/16

Reinforcement Placing

Bridle

Point

Bridle

Point

20 3/16

Drawing # 4

Top Reinforcement

Bridle Point Reinforcement

Side Reinforcement

Bottom Reinforcement

3

/4

3/4" mark for sew line

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the kite first. Fold other half on top of this and sew along the kite edges to form the

pocket. ( see photos)

4) Place 1 sail back side down on work surface. Place 16 aluminum ring holder with ring addedat top bridlepoint placing it into this seam, see photo. Repeat for lower bridle point with

2 aluminum ring holder with ring in place. Align 2ndhalf of sail on top of first with good

side down. Sew both sides together 3/8from edge on sew line from drawing 4

a. . ( I use seamstick to hold everything together)

5) Open up sail6) Align both halves with backsides together.7) Sew from edge to form spar pocket stopping 1 from bottom leaving room to

insert spars, this is where the bottom spar pocket starts.

8) Sew top of sail shut forming the top of the spar pocket9) Insert folded in half tail holder past bottom reinforcement bottom.

a. Sew this from bottom of spar reinforcement to tip of sail.

10)Sew bottom of reinforcement to form bottom of spar pocket.

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Assembly:

1) Fit and insert center spar by inserting it opening of bottom of sail all the way to the top.2) Assemble and tie spreader making sure both sides of the spreader are equal in length,

cutting may be necessary.

3) Tie bridle to rings making sure to have the short part of the bridle attached to the top ring.You are now ready to fly, enjoy!!!

Any questions contact:

Mike Dallmer

306 Friendship St.

Phila., Pa 19111

215-722-4092

mikedallmer@verizon.net

Plans written February 2011 for workshop given by Mike Dallmer to the South Jersey

Kite Flyers

mailto:mikedallmer@verizon.netmailto:mikedallmer@verizon.netmailto:mikedallmer@verizon.net