Double Malay Stack 1994

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Cervia, Italy, 29th April 2022

Double Malay Stack 1994
14 kites, each square 79.2 x 79.2cm, (corrected 4th September 2023) 2 horizontal, 7 vertical
Weight: 2.5 kg
tails: 12 metres on each kite
Total size: 1.12 x 2.24 x 12 metres (8.8 square metres)


Windspeed 9mph Portsmouth 30/07/2022.
Windspeed 14mph Portsmouth 29/07/2023.
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Notes...

Poly tubing for wide spreaders fixing replaced. Replacement dowel purchased 08/2019. Major un-twisting done 12th February 2020
Parts reviewed in image above prior to Portsmouth 2021.
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The dihedrals are 8mm for the spine and should be the same for the spars. We will consider replacing the dihedrals as shaving down replacement spars is not ideal.
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All the elements have been measured 'for the record' as at 12th September 2023. The 1:1 drawing has been done in CADintosh X and smaller versions exported for illustration. A diagram of bridling line lengths is being prepared.

Configuration and Replacement parts

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Construction image 20/03/2019.

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12th February 2020
Rusty components replaced
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12th February 2020
Tails removed
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12th February 2020
Sails untwisted and wrapped...
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1st April 2022.
Checking the replacement dihedral.
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Replacement dihedral in grey.
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2nd April 2022.
New dowel spreaders prepared.
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6th April 2022.
The old dihedrals still had debris from drilling to 8mm attached.
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5th July 2022.
Two replacement carbon spreaders and two spares prepared.
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After Portsmouth 2023 some spar pocket repairs were noted and one of the last pair of sails needed to be untwisted as it had been flipped. The central chromed steel loops will need to be replaced as they are rusting and also are a trap for the lower bridle leg lines.
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On the bench in preparation 18th August 2023.
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One white tail removed prior to flipping the sail back to the correct position. Re-positioning the bridle lines correctly for the flipped sail is a three dimensional puzzle.
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The tails are secured ready to be disconnected during maintenance.

Replacement stainless steel rings have been ordered and the pockets re-sewn as needed 21st August 2023.
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The bridle lines have been measured, for the record. The emergency repair knot fixing one of the lower bridles to the main line appears to have held position. The knot was tied in the downpour at Berrington and the kite flew there and subsequently at Portsmouth.
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Ring replacement size comparison.
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All set.
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Consolidating the edges of the spar pockets where the fabric is fraying seemed like a good idea.
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A practical solution preventing accidental closure by the PVA using glossy electrical tape.
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The 1mm polyester line arrived 30th August so a complete set of lower bridle lines have been prepared. It is to be hoped that this line is sufficiently 'stretchy' compared to the original.

At this point, with the sails on the bench it seemed sensible to take basic measurements and consider the possibility of measuring each sail layout!
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The measurement of the sails were previously given as 90 x 90cm but this was not correct as at 4th September 2023!
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The sails are 79.2 x 79.2cm squares, 112cm diagonally.
The bridle lines have been re-measured as at 13th September 2023 but there is not much real consistency with a previous attempt. Where lines have been broken and retied replacements have now been set in parallel, secured with prusic loops. Some previous markings on the last set of main lines were noted. The distances between the pairs of kites should be recorded at some point but this was not practical on the bench!
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All done, ready for the tails to be re-attached.
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Slowly sorting out the re-configuration of the long cross spars, January 2025.

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Page Updated January 2026 Felix Mottram