Very good, and much obliged, gents!
Brett: Makes a dude wonder how that "feature" got built into the range of weight and line diameters?!
We know exactly why. The pull test itself (the 10Gs) is about 4x the normal pull of a stunt plane, which is around 2.5 Gs., that is normally shared by the two lines in a test, When a single line lets go, all the pull is applied to the single remaining line, so it has been tested to ~2x the load it will see in a failure, which we thought was a good margin.
When it came to determining the line size breaks, we used the accepted industry standards for line test strength, so that the lines you have to use have a nominal test strength of what it sees in a failure with the similar margin. For example, suppose you have a 63.9999 ounce airplane. You select .015 lines, and pull test ~40 lbs. so each line sees ~20 lbs in a pull test. The nominal industry standard for the test strength of .015 2-strand stainless-steel lines is about 40 lbs. So even during a pull test, you have a margin of about 2 over the expected lowest-failure-tension. This sort of margin over the test strength is intended to reduce the possibility of fatigue failures - because you don't want to repeatedly test something to exactly its rated strength over and over.
Of course, the sizes were arrived at by doing this in reverse, calculate the pull, throw reasonable (but not crippling) margin on everything. It just happened to fall right in the middle of the current range of airplane weights.
The airplane pulls about 10 lbs total (2.5x4 lbs). That means that after a failure. your .015 lines see about 10 lbs, which is half the pull test and 1/4 the nominal expected strength of the line.
Having said all that, even if you could guarantee that you would never go over the break point in weight, you might try the next size up lines anyway, for performance reasons.
Brett