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Some pics building a XPS, paulownia, carbon foilboard

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Breze
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Some pics building a XPS, paulownia, carbon foilboard

Postby Breze » Mon Oct 01, 2018 10:21 am

Wishlist of the new board: Light,strong, ketos like scoop and outline,simple long 30 cm railsystem , 138x48 2.5 cm Scoop 13cm
Build of materials that i easily can buy online and at the lokal hardware store.

Step 1 : Making mdf templates for the outline and scoop-rockerline by hand drawing and using some bend wood strips.

Step2: Hot wire cut the srline by using 2 mdf templates fixed at the sides of the Xps https://www.austrotherm.de/produkte/aus ... top-50-sf/ the 500 or 700kpa are better than the normal 300kpa.
I made two cuts to get a 2 cm blank. The Xps blanks were heavyly weighted down for cutting, afterwards glued together with epoxy.

Step 3 : I glued together the mdf sr line templates, building a simple rockertable.

It looks like that

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Step 4 : Cutting the 3mm paulownia strips and glueing together to get the deck for the sandwich. Handsaw with guide rail.
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Breze
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Re: Some pics building a XPS,paulownia,carbon foilboard

Postby Breze » Mon Oct 01, 2018 11:03 am

Step 5 : Glueing 3 strips of 2.5 cm wide paulownia on the rockertable, to get the two stringers.
Building the track or railsystem of solid oak and carbon.The bottom slot is 8mm. Top slot 13mm to jam the ss M8 nuts.
For laminating the carbon inside the oak boards i built a template or kind of male profile.
The idea is this open track

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Step 6 Sanding and filling the Xps with epoxy and glass bubbles/microballons.Used 60er grit and done this two times. Caution Xps tend to delaminate later if this isn`t made carefully

Step7: Cutting the slots for the two stringers and the rails.Glueing them in with some glass and epoxy mixed with microballons and cotton.Patch of 200g cabon on the rails overlapping the stringers.
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Sanding and filling the Xps with epoxy and glass bubbles/microballons.Used 60er grit and done this two times. Caution Xps tend to delaminate later if this isn`t made carefully!!!
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Step 8 : Laminating the deck under vakuum: Xps then 80g glass then the paulownia with vakuum in the sack
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after sanding and filling, cutting the outline, installing the inserts simple M6 nuts with flange
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Frontinsersts little bit too wide in the middle, will fix this.

Breze
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby Breze » Mon Oct 01, 2018 11:12 am

Step?? Cutting the rails / edge with a knife

Step ??? Laminating 300g triax carbon on top, then on button , in the vakuum sack. The slots of the rails filled with plasticine

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Epoxy barrier primer and some children with edding

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Naked weight 3.1-3.2 kg

Breze
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby Breze » Mon Oct 01, 2018 11:51 am

The board turned out stiff and solid with a patch of 450 g triax carbon on the bottom over the rails.
Here you can see the unshaped rockerline13 cm scoop ,1cm rocker, touchdowns are easy.
turn your head 180°
Image

The long open track system is nice to have and no problem for my feet. It is really solid and easy to install the foil

opie
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby opie » Mon Oct 01, 2018 2:04 pm

Nice! And thanks for all the photos.

Pemba
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby Pemba » Mon Oct 01, 2018 2:56 pm

Yes, nice. Making it look easy. Huge scoop by the way.. Any idea how much time you spent on it ?

Breze
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby Breze » Mon Oct 01, 2018 5:44 pm

Scoop is just right for me bc i cutted about 5cm the nose off.
I started in spring, ended august.Only working about 2-3 hours at the weekend.If working straight forward it would be only one week.
Costs: 30 Eu XPS, 5o Eu Epoxy, 28Eu paulownia 100 Eu
Carbon. ... all in all 300 - 350Eu

RichR2
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby RichR2 » Thu Oct 04, 2018 8:30 am

Always good to see how others go about their builds, nice job!. Im interested in how you made your mast track boxes and how they are holding up, any photos of that stage of the build?

Breze
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby Breze » Sat Oct 06, 2018 8:37 am

Sorry no photos .I`ll try to explain. I found 2 pieces of solid oak 34x5x2 cm. Made the slots wth a router. Upper slots abot 15mm , getting a 13mm wide slot after lamination, to jam the nuts. Same on the bottom but with 10mm getting out 8mm for the M8 screw.
Laminating the walls of the rails with the 90° step was abit tricky. I cutted stripes of 245g carbon one sided with thermoplast fixation, so no frazzle when cutting.
I sealed the outsides of the oak with tape, to not glueing them together. Made a plug to get 13 and 8mm slots. Plug was made of wood and tape.
The plug is 13mm wide in the middle and 8mm at both ends. The wider middle part is 2 times the nut hight long.
I wetted the carbon and oak surface with epoxy by using a brush. Fiddeled the carbon into the slots then pressing it to the walls by using the plug.
The two rails where clamped together, face to face with the wider 13mm side. So the plug alinged the slots symmetrical.The outside of the two oak rails aligned and fixed with clamps. Made this in a one shot operation to get two symmetric rails.
If you have some solid oak boards, the hole bling bling carbon laminatio is not necessary, just sealing it with some epoxy is enough.
Of course i had to do some fine work with a file at some parts of the rails.
The big washers and the solid oak with top and bottom patches of heavy 245g and 450 triax makes the hole board strong enough.
I think the paulownia stringers are not necessary for strenght but nice for " routing" the top and bottom of the XPS , works as a guided rail.
The top sandwich with 80g glass 2.5 mm paulownia and 300g triax is needed when working with XPS or EPS core, to avoid heel dents and stiffen the board in the direction of compression.
Sanding with rough 60 grit or even 40 grit and filling with epoxy micro ballons after removing all the dust has to be made very carefully when working with XPS.
Also there are some sorts of XPS witch tend to degas.Painting the black epoxy with some white epoxy barrier primer is also needed to get no delamination problems because of the heat.

Then you have a problem like this : 1000 Eu board heat damage
https://www.youtube.com/watch?v=4SjLcYQh9cQ
https://www.youtube.com/watch?v=IXesqSX_aiU

TomW
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Re: Some pics building a XPS, paulownia, carbon foilboard

Postby TomW » Sat Oct 06, 2018 3:30 pm

Well done! What's it weigh?


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