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A return to building

Forum for hydrofoil builders.


RichR2
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A return to building

Postby RichR2 » Sun Jul 01, 2018 2:06 pm

P1000656.JPG
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.
P1000619.JPG
EPS insulation sheet for blank and PVA was used to stick it to achieve the size required
P1000621.JPG
Rocker was hot wired (13cm with 2cm tail kick)
P1000624.JPG
Plan shape cut out and stringers stuck in with resin and glass bubble mix.
P1000625.JPG
Blank hand shaped and sealed with resin and glass bubbles
P1000627.JPG
Layer of 200g e glass and closed cell foam stuck on top ( no vacuum set up so gravity and bricks used)
P1000628.JPG
10mm corecell foil plate reinforcement inserted (layer of 200g e glass underneath)
P1000630.JPG
Board laminated by hand (no vacuum … just squeegee!)
P1000631.JPG
Footstrap inserts stuck in with resin glass bubbles mix before laminating deck
P1000632.JPG
Routing out for foil track boxes
P1000634.JPG
Track boxes installed wrapped in several layers of e glass and resin glass bubbles
P1000635.JPG
Epoxy sanding coat rubbed back
P1000642.JPG
White primer applied and rubbed back
P1000643.JPG
White car aerosol spray finishing coat rubbed back and polished
P1000655.JPG
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.

plummet
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Re: A return to building

Postby plummet » Mon Jul 02, 2018 1:34 am

Fantastic build man. It looks professional

RichR2
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Re: A return to building

Postby RichR2 » Tue Jul 03, 2018 7:40 pm

Thanks

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SaulOhio
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Re: A return to building

Postby SaulOhio » Wed Jul 04, 2018 2:36 am

RichR2 wrote:
Sun Jul 01, 2018 2:06 pm

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.
It makes a difference when jumping. Mine is VERY heavy, and I don't like to jump it. I've done it, but that much weight swinging from my feet is scary.

opie
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Re: A return to building

Postby opie » Sat Jul 07, 2018 12:46 pm

Thanks for this, lot's of good info and pictures.

It's cool to see what someone with skills is able to achieve without all the tools available.

TomW
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Re: A return to building

Postby TomW » Sat Jul 07, 2018 5:58 pm

Pretty good man! a Straightforward build without excess. Not sure why you ended up at 3,8 kg. But you're not far off. 3,2 kg is what you can get to.

If you want at try again: You don't need the full length stringers. Or transversal plywood stringers for the boxes. I would put HD foam block, deck to bottom around the boxes. Only 10-15 mm Bigger than the box area.

Your deck sandwich is needed. you might get away with less glass on bottom..

Hope you enjoy it!

RichR2
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Re: A return to building

Postby RichR2 » Sun Jul 08, 2018 9:18 am

Thanks for the kind words. My next two builds are underway already so they've had stringers stuck in, so can't change that, but will drop the two lateral box reinforcements. I am going with a lighter lay up this time (see my lay up thread) and Ive been able to borrow a vacuum pump so will vac bag this time. I'll share how things have gone once they are finished.


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