The plastic lugs are not missing - a lot went missing with the missile failure. The setup was as per instruction. I regularly look at this and there was no evidence of imminent failure, the rope is not frayed at all. I must admit that I did not disassemble the mechanism to look at the anchorage points, that is a time consuming thing to do. My fault - I doubt it - there is no manufacture specific inspection instructions nor suggested replacement intervals.
There is another problem I have had. With my Ocean Rodeo 14.5 kite it has occasionally disconnected from the hook, most dangerously on land when holding at the 12 o'clock position. I do not have the issue with my North 12 and 10m kites. The Ocean Rodeo has a soft stick (to be polite) on the chicken loop, with the hook design and flexible fixing point of the Dynabar at the vertical position it can and does want to open. A deeper or more curved hook would probably eliminate this issue.
On looking elsewhere on this site it seems that many have illustrated methods to have secondary failsafe devices - pity I did not see them. It would suggest that a few others have had or perceived this as a potential problem. I've perused some of the solutions and worry that they'd even work, or become a danger in there own right. The manufacturer needs to provide one, that has had the proper rigorous engineering and testing applied.
I have briefly looked at other sites for Dyneema failure. Mountaineering sites are good ones. They are using 8 through 11mm ropes and can get failure see
http://dmmclimbing.com/knowledge/knotting-dyneema-vid/ . Is the rope on the Dynabar simply too undersized for the job ? There are a number of other factors to consider. The rope passes into a hole at close to 75 to 90 degrees to the length of the rope. Protection against fraying is a thin plastic sheath, which in itself provides a pinch point. There should be a radius for direction change, the greater the better, in this design it is a pinch point. Inspection on the underside is made difficult because of the disassembly complexity, if due to the narrow radius there is internal fibre failure, visual inspection would show nothing. A better design would be to have a system where the rope is anchored on the outside of the bar.
Dyneema rope simply snaps, and I've witnessed a dangerous result on my person. With a short rope there is no elasticity for dynamic load, and Dyneema has stretch anyway. For those who own and love the Dynabar, don't be cavalier, take whatever steps is necessary to prevent a similar incident from occuring to you. I'll be examining the steel runner option for the time being, if I go back to rope it will be with 10mm cord with a Ronstan pulley to provide radius.