I see your belt sander on the table. I've stayed well away from those things for years now! Fast but terrible for getting a flat surface!phuqit wrote: ↑Fri Jul 13, 2018 12:09 pmAlright, finally started with the real thing. Made a shape from the PVC board, then cut out the core ~1cm less than the final shape, will be sanding the edges and tips from 10mm to 3mm, then will pour the epoxy + carbon powder rails and inserts/fin reinforcements. Can't get proper PU or ABS rails within reasonable timeframe, so epoxy will have to do for now.
1. Do you mean the rocker flattened out and bent the other way between the foot pads? 9mm thickness in the centre with 250gr carbon (0 deg, I assume) both sides should be plenty stiff, especially with some concave.phuqit wrote: ↑Sat Jul 21, 2018 3:27 pmFew things to do differently for the next board:
-Use a thinner core. 9mm at the center actually bent worse than the thinner tips, so the rocker profile is somewhat weird. Works just fine though.
-To make sure infusion works on the bottom, make 1.5mm holes at 5cm intervals, and tiny grooves diagonally to them. Pretty sure that would solve that dry patch issue.
-ABS rails. Found a 3mm x 1m x 2m sheet @ 40€ here locally, will try to cut out something like 1cm wide strips, and place them on the edges, and bend it with a heat gun. After I sand and flame it, of course.
-Inserts are probably fine to do with epoxy+carbon powder mix, just make sure I tape the bottom of the hole, or don't route it completely through, so it doesn't run out. I'll give it some more thought, perhaps pressing the flanged nuts into polyamide or nylon holders would be better? Not sure if epoxy binds to PA or PE11 though...
-Anything less than 3mm thickness is very hard to machine using a belt sander. I'll probably just cash out for the CNC job.
-300 biax +250 uni each side is bloody strong and flexible. If I can CNC the edges of the wood core to 2mm, it would probably be perfectly strong and flexy enough for kiteboarding. I could probably use the same amount with a foam core.
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