Having made 4 windsurf boards and 8 kiteboards in the past I recently got the building urge again (after having got rid of all my vacuum equipment many years ago). So, this is my first attempt at a foil board. Hope its useful for any new builders out there to see that you don’t need lots of special kit to do a build.
Board Specs:
125cm x 48cm x 4.5cm
EPS foam core with 3mm closed cell foam sandwich deck
Two full length ply stringers, and two full depth ply supports for foil tracks (chinook)
Deck Laminate : 3x 200g e glass (1 under closed cell foam), 100g UD carbon, 200g plain weave carbon patch under foot area.
Hull laminate: 3x 200g e glass, 100g UD carbon, 200g plain weave carbon patch from foil plate to 2/3rds of length, 200g e glass patch under and over corecell plate reinforcement area.
Finish: Epoxy sanding coat, Jotun white easy primer, White car spray paint.
EPS insulation sheet for blank and PVA was used to stick it to achieve the size required
Rocker was hot wired (13cm with 2cm tail kick)
Plan shape cut out and stringers stuck in with resin and glass bubble mix.
Blank hand shaped and sealed with resin and glass bubbles
Layer of 200g e glass and closed cell foam stuck on top ( no vacuum set up so gravity and bricks used)
10mm corecell foil plate reinforcement inserted (layer of 200g e glass underneath)
Board laminated by hand (no vacuum … just squeegee!)
Footstrap inserts stuck in with resin glass bubbles mix before laminating deck
Routing out for foil track boxes
Track boxes installed wrapped in several layers of e glass and resin glass bubbles
Epoxy sanding coat rubbed back
White primer applied and rubbed back
White car aerosol spray finishing coat rubbed back and polished
Finished board with trim
Came in heavier than I was hoping at 3.8kg but as I’ve heard that the only time that makes a noticeable difference is when you’re carrying it, I’m not too worried. Just waiting for the first opportunity to test it out.