Re: Cam Battens
Yeah, I've broken a bunch of these in my Rebels as well. At first I thought it was how I was folding it, but then I started checking and nope it was when the kite hit the water. My kite hit the water a lot when I was a beginner, then it didn't for a few seasons, and now it is hitting the water again as a go for more and more advanced tricks.
My shop was really supportive and gave me a bunch of replacement battens no-cost, but there's only so long that will work. So I took things into my own hands.
The North Rebel and Rhino battens are Nylon 6/6, near as I can tell. Nylon is nice and stiff but it has low impact strength - it shatters. Especially when stressed (bent around the LE) and struck (hitting the water).
I think a better material would be ABS - similar stiffness as the Nylon but much higher impact strength. So I got some 3/16" ABS plastic welding rod from McMaster-Carr: item 7889A97 at http://www.mcmaster.com. (~US$17)
This comes in a continuous coil. I cut it to length with side-cutting pliers, round the ends with a file, and presto: all the cam battens I want.
They aren't indestructable - I've broken these as well, but I have as many as I want, whenever I want, and they're nearly free, so who cares if they break?