Exult's Gentle Breeze

I wouldn't try this on the Illusion. When assembled, the Illusion has a lot of stress at the center T because of the curvature of the kite when assembled. The Illusion had special, specific lower spreaders that were reinforced at the junction point, they are exclusive to the Illusion.

The problem with trying to repair a spar on a kite is that if the repair fails, there is the risk that a broken spar will puncture the sail. 

10 hours ago, RobB said:

I wouldn't try this on the Illusion. When assembled, the Illusion has a lot of stress at the center T because of the curvature of the kite when assembled. The Illusion had special, specific lower spreaders that were reinforced at the junction point, they are exclusive to the Illusion.

In the text I explained that it was the lower leading edges (perhaps you did notice?) of the Illusion that easily broke (and that they snapped in two pieces and therefore would require some other approach than explained in the main part of the text and images).

If a lower spreader of the Illusion broke at the joint as you described, I'd wind some extra turns of glass fibre there thanks to the knowledge you shared. With a DIY approach comes liberty to have it your way (Swedish proverb: "Yourself are the best farmhand"). You seem to be well familiar with the Illusion design, if I may, I'll ask for your opinion before future Illusion (spare part) repairs.

10 hours ago, RobB said:

The problem with trying to repair a spar on a kite is that if the repair fails, there is the risk that a broken spar will puncture the sail. 

[rant] The problem with flying is that spars might break and might risk puncture the sail - there is obviously no point in leaving home and flying kites. [/rant]
The problem with the Illusion spars (as you expressed in http://kitelife.com/forum/topic/6637-older-prism-illusion-kite-need-help/#comment-53325 ) is that that it is difficult to get them. So given the choice, should one try to repair the Illusion and use it for what it was intended for or should one forever return it to it's sleeve? I'm not there yet (got a working Illusion, two snapped LLEs and a spare lower spreader with only the nock broken), but would like to be well prepared if possible just in case and not have the lack of spares limiting my flying. And if it would happen, a puncture in the sail i.e., I could Teldar patch it. In my years I've never had a broken spar induced sail tear. I've broken/worn out sail/fabric parts about six times and spars about ten times (not counting C-clips, nocks, fittings...). But perhaps the Illusion is more sensitive here?

Regarding the lower spreader of the Infinity repair (which is what the main part of the text is about), the extra layers at the repair point, are at least as thick as the original tube wall thickness, so I'm quite optimistic here. Would it break, well then have learnt something and I'll learn something more during the next repair.

And, b.t.w. thank you for commenting!

 

I hope your repair is standing the test of time. I have attempted spar repairs in the past, only while waiting on replacements. Never had one fail, but I only flew on the repairs once or twice before the new ones came in. Please don't get me wrong, I respect your effort.

I will say... I've had spars fail and the pieces ripped the sail. Really, nothing worse than that... without replacing a panel, there's no way to fix a sail and make it like new... you can always tell, and if it's a special kite, it's heartbreaking. 

Best of winds to you !