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BHL4-31 "HERCULES"
BARRETINA HYPER LITE 4

HERCULES
 Figure 1. Ground Handling HERCULES single skin 31 m2


1. DESCRIPTION

BHL4-31 HERCULES is the BHL4 single skin prototype made by Lance Kraftenberg, Ticities, Washington (WA), USA. Escaled from the 24 m2 version. Completed in February 2022, currently in testing and adjustment phase.

Lance offers us many photos with many interesting construction details that may be of interest to other builders.


2. PLANS

Scaled from 24 m2 model
LEparagliding files: leparagliding.txt bhl-5p.txt bhl-4p.txt bhl-tube.txt lep-out.txt

Placard
Figure 2. Placard


3. PHOTOS

A. GROUND HANDLING

1 20220402_075759
20220402_075759
 2 20220402_075806
20220402_075806
 3 20220402_075927
20220402_075927
4 20220402_075949
20220402_075949
 5 20220402_080536
20220402_080536
 6 20220402_081123
20220402_081123


B. RISERS

1 01. Measure and cut strips
01. Measure and cut strips
 2 02. Measure and cut squares for harness attachment
02. Measure and cut squares for harness attachment
 3 03. Stack two straps on top of each other and clip red square around strraps
03. Stack two straps on top of each other and clip red square around strraps
 4 04. Sew each side of red square
04. Sew each side of red square
5 05. After both sides sewn
05. After both sides sewn
 6 06. Fold straps in half and sew top of red together
06. Fold straps in half and sew top of red together
 7 07. Cut color squares
07. Cut color squares
 8 08. Click color squares to top of risers
08. Click color squares to top of risers
9 09. Sew
09. Sew
 10 10. Measure and cut brake handle straps
10. Measure and cut brake handle straps
 11 14. Embroider paraglider name
14. Embroider paraglider name
 12 15. Cut out name
15. Cut out name
13 16. Fold in half and sew seam
16. Fold in half and sew seam
 14 17. Turn right side out and slide onto brake handles
17. Turn right side out and slide onto brake handles
 15 18. Sew handles together with ring
18. Sew handles together with ring
 16 19. Cut brake line guide
19. Cut brake line guide
17 20. Sew ring onto brake line guide
20. Sew ring onto brake line guide
 18 21. Sew velcro onto brake line guide
21. Sew velcro onto brake line guide
 19 22. Attach brake line guide to riser
22. Attach brake line guide to riser
 20 23. Completed risers with brake handle
23. Completed risers with brake handle
21 24. Cut square for riser bag
24. Cut square for riser bag
 22 25. Fold in half and clip together and sew
25. Fold in half and clip together and sew
 23 26. Fold top down and sew
26. Fold top down and sew
 24 27. Finished. Turn right side out and feed drawstring through opening
27. Finished. Turn right side out and feed drawstring through opening
25 28. Risers and brake handle with riser bag
28. Risers and brake handle with riser bag


C. WING

1 01. Portion of the 1123 pages to print pattern
01. Portion of the 1123 pages to print pattern
 2 02. Putting pattern together
02. Putting pattern together
 3 03. Completed panel pattern
03. Completed panel pattern
 4 04. Completed rib patterns
04. Completed rib patterns
5 05. Rib 17 fabric cut
05. Rib 17 fabric cut
 6 06. Rib 16 with rod pocket and attachment reinforcements (Ottertex Polyester Ripstop)
06. Rib 16 with rod pocket and attachment reinforcements (Ottertex Polyester Ripstop)
 7 07. Cutting lower panel
07. Cutting lower panel
 8 08. Cutting reinforcement (Ottertex 210d Polyester Canvas) for elliptical inlet
08. Cutting reinforcement (Ottertex 210d Polyester Canvas) for elliptical inlet
9 09. Attaching inlet reinforcement
09. Attaching inlet reinforcement
 10 10. Inlet complete front
10. Inlet complete front
 11 11. Inlet complete back
11. Inlet complete back
 12 12. Sew upper and lower panel 17 leading edges together
12. Sew upper and lower panel 17 leading edges together
13 13. Lower panel 17 pinned to rib 16
13. Lower panel 17 pinned to rib 16
 14 14. Sew lower panel 17 to rib 16 and insert attachment points
14. Sew lower panel 17 to rib 16 and insert attachment points
 15 15. Sew second seam along bottom of rib 16
15. Sew second seam along bottom of rib 16
 16 16. Sew attachment points to rib 16
16. Sew attachment points to rib 16
17 17. Sew upper and lower panel 18 leading edges together
17. Sew upper and lower panel 18 leading edges together
 18 18. Fitting reinforcements to lower panel 18
18. Fitting reinforcements to lower panel 18
 19 19. Attach reinforcements to lower panel 18
19. Attach reinforcements to lower panel 18
 20 20. Reinforcements on lower panel 18
20. Reinforcements on lower panel 18
21 21. Back of lower panel 18
21. Back of lower panel 18
 22 22. Attaching upper and lower panel 17 and 18 to rib 17
22. Attaching upper and lower panel 17 and 18 to rib 17
 23 23. Rib 18 finished
23. Rib 18 finished
 24 24. Turn upper and lower panel 18 inside out and pin edges together
24. Turn upper and lower panel 18 inside out and pin edges together
25 25. Sew along edge, inserting attachment point as I go
25. Sew along edge, inserting attachment point as I go
 26 26. Sew attachment points down to reinforcements
26. Sew attachment points down to reinforcements
 27 27. Turn upper and lower panel 18 right side out
27. Turn upper and lower panel 18 right side out
 28 28. Close up of lower panel 18
28. Close up of lower panel 18
29 29. Cutting 2 inch strips to make half inch double-folded bias tape
29. Cutting 2 inch strips to make half inch double-folded bias tape
 30 30. Fold strip with bias tape tool and iron on light setting
30. Fold strip with bias tape tool and iron on light setting
 31 31. Wrap bias tape around cardboard for future use
31. Wrap bias tape around cardboard for future use
 32 32. First sew reinforcements to rib, then rod pocket, next sew double-bias tape along edges and finally sew on attachment points
32. First sew reinforcements to rib, then rod pocket, next sew double-bias tape along edges and finally sew on attachment points
33 33. Sew panels 14 and 15 to rib 15
33. Sew panels 14 and 15 to rib 15
 34 34. Rib 15 completed
34. Rib 15 completed
 35 35. Bottom view of completed cells 15-18
35. Bottom view of completed cells 15-18
 36 36. Progress pic
36. Progress pic
37 37. Progress pic
37. Progress pic
 38 38. Progress pic
38. Progress pic
 39 39. All panels done
39. All panels done
 40 40. All panels done
40. All panels done
41 41. Insert nylon rod into rod pocket
41. Insert nylon rod into rod pocket
 42 42. Close rod pocket
42. Close rod pocket
 43 43. Finished rod pocket
43. Finished rod pocket
 44 44. All rod pockets done
44. All rod pockets done
45 45. All rod pockets done
45. All rod pockets done
 46 46. Sewing bias tape along trailing edge
46. Sewing bias tape along trailing edge
 47 47. Sewing bias tape along trailing edge
47. Sewing bias tape along trailing edge
 48 48. Preparing brake attachment point
48. Preparing brake attachment point
49 49. Brake attachment point clipped onto trailing edge
49. Brake attachment point clipped onto trailing edge
 50 50. Brake attachment point done
50. Brake attachment point done
 51 51. Brake attachment point done
51. Brake attachment point done
 52 52. Attach information placard
52. Attach information placard
53 53. New stuff sack
53. New stuff sack


Many thanks to Lance Kraftenberg for sharing the details of his project.

Others prototypes from Lance: gnuA4 27 m2 ML "Origin"


LAB NOTE: Build a paraglider at home is a very complicated task (even simple skin), and requires many hours of work. Previous experience is required, and very inventive. As always remember that: The free flight implies risks that can only be known and they can be controled with a suitable formation on the part of a recognized school. Not test wings without knowing their functioning. The construction and test of experimental wings without certifying requires deep knowledge of what is being made.