Basket Design:

Basket size is depends on the size of the balloon and the number of people to be carried.  A basket for 4 should measure at least 4.6 ft X 4 feet and be 3.5 feet high (interior measurement).  Most baskets are rectangular not square.  Each basket is hung to the by suspension ropes.  Each side of the basket must have at least two maybe three suspension ropes.  The suspension ropes pass under the floor of the basket and are protected by wicker so they are not damaged by sharp objects or metal support channels.  Most support lines will carry at least 3100 lbs individually. 

For short trips of a couple of hours in duration 3 sq ft. of floor area per passenger is sufficient, although rather crowded.  For longer trips for racing, more than double this area may be needed.  In any case the minimum size of a basket -- even if only one person is carried--should not be less than 30 inches in width and 36 inches in length, in order to afford sufficient protection when landing in a strong wind.

Height will vary from 30-48 inches.

The materials used in basket construction are usually of wicker because it is strong, durable, and flexible.  The basket is is woven like any ordinary basket and reinforced in places exposed to impact and wear. The top edge is stiffened by a frame of wood or heavy cane to withstand the strain of the basket ropes.

Across the bottom are placed several hardwood skids which protect the plywood or wicker floor and support cables that form a support cage for the basket.

The basket suspension ropes usually number usually 6 to 8 in number. These ropes extend 3 to 4 feet above the edge of the basket and are terminated in eyes which attach to the toggles or carabineers on the load ring..

On the outside of the basket are fitting rope handles which are used for carrying the basket and which can also be used for supporting sandbags during the flight.

A line is often attached all around the inside of the basket about 1 foot above the floor.  It is used for passengers to hold when the basket is dragged across the ground while landing in a strong wind.

The inside of the basket is usually lined with some type of fabric gear wall that has many pockets for storing equipment during the voyage.

In 2009 we built a new gas basket for the 2009 America's Challenge Race.   Here are some pictures about how we built the basket.  It took 3.5 days to build 95% of it.  Just need to add the bolster cover and load test it before heading to New Mexico in Oct. 

 Gas Basket Construction Pictures