Thanks guys for your interest
Fabric I have available is either Chikara or something perhaps bit lighter from PG's. Good quality stuff and I'm not seeking anything more light weight.
I have old valves available and one pump is of course not needed for one strut kite. Actually having separate valves gives an opportunity to have higher pressure in strut than in LE. Then strut can have a bit smaller diameter than usually for same stiffness making it a bit lighter.
I think I'll have that one strut and design more like Ultra or Mono than like Cloud to aim for a bit more universal kite. I haven't tested a Cloud however. I'm a bit worried about flutter even with one strut, because it is there in Ultras when looping... Clouds have smooth LE and quite high panel count which I like and will have in my kite.
Having some Airush style diagonal webbing is worth considering. I don't know if it have to be dyneema, actually it worries me a bit because diagonal cloth stretch and dyneema stretch are so different. But it seems to work.
#downunder: I know your problem, actually I tried similar idea couple of years ago. I removed struts and cut LE to an angle to have wingtip shaped more than I liked and to get rid of heavy dacron. Unfortunately I didn't cut LE to correct angle so it became a weird at least and I also had difficulties to attach remaining canopy neatly to LE. That project is still unfinished and I will probably leave it as a kite for some spare parts and fabric.
I have of course plans available but I doubt if they are any useful for your project. Different size, different shapes etc. If you took some measurements from Crossbow and then design your own model it could help, but nor measuring neither designing to match is not quite simple task.