Paul1 said..
Seems like it is a seat harness issue, so maybe you guys need to progress to waist harnesses to save your money on bars.....

Was expecting someone to say 'Time to start unhooking' probably right! Well at least some of the time.

Started kiting in 2009 with a new Fusion from the US... the stitching on the leg straps was already coming undone when it arrived, but I used it for 2 years anyway. Got a new one in 2011 but after a few sessions noticed one of the straps hadn't actually been stitched onto the harness...! The end was tucked under a cosmetic seam and just popped out.

Got a 2012 Fusion as a warranty replacement but, like the original one, the leg straps are ripping away from the body - and have been for a year. VERY poor design at that point - they should be stitched to webbing, not the neoprene soft part!

A spreader bar broke at both welds on holiday in Thailand. Broke just after a jump, on the water... had to buy a Mystic seat harness (that's too small) to get through the holiday.

Had another spreader bar break recently, at the top of a good jump - thankfully, only one side went so I landed gently then babied the kite onto the beach. Needn't have bothered cos the remaining side is bloody strong - can't bend it with my hands at all.

Problem is, I greatly prefer the fit and feel of the Fusions over the other harnesses I've tried on... and Dakine is one of the few companies that make XXL too.

Mystic hook seems a slightly better design - narrow so the CL can rotate left to right easily. Don't like the clicker at all and it doesn't hook under enough - had the kite unhook when I splashed down from a jump and it flew out of my hands AND ripped the leash right off the harness... kite tumbled downwind until someone caught it on the beach :o

Got a Renegade to see if I like waist harnesses... I don't :lol:

Nope, the leg straps are just stitched onto the neoprene at the bottom of the harness. I'll take a photo when I get home, if I remember.

Wear in other places doesn't bother me so much - kind of expect it, cos the harness is pretty soft 'n' comfy otherwise.

Anyone attempted making their own spreader bars...?

Yep my seat harness snapped at the hook weld too a couple of months back ... that's when you realise how useless your leash is attached to that hook.
Thank you scarbs beach rescue!

Tightlines...that hilarious