Pocket board building

[loco4viento]

Beautiful work!

[wallydog]

Beautiful work!

Agreed
How did you laminate the wood to the foam? Looks like a concave deck.

[direnc]

Beautiful work!

Agreed
How did you laminate the wood to the foam? Looks like a concave deck.

Thank you guys! Yes the deck is concave so as to make the board stiffer. The plywood is glued to XPS foam with marine PU wood glue. Here is how I did it:
Applied glue to all surfaces and joined them over a wooden bench.
Screwed a 20x60x2cm block of wood on top. (15cm from the back of the board, to keep foil mounting area flat).
Raised the rails by 18mm using pieces of wood.
Raised the nose by about 12cm to form nose rocker.
Weighed it down with salt bags/water bottles etc.
Clamped/screwed any areas that have gaps between layers.

They have 2x200g glass on bottom and 1x200g on glass on top. Also extra layers over foil mounting area.

[wallydog]

Thanks. So you do the top ply, foam core and bottom ply in one glue-up step? WOW.

[direnc]

Thanks. So you do the top ply, foam core and bottom ply in one glue-up step? WOW.

Yes, all done at once. Not difficult, only have to be quick while spreading the glue.

[wallydog]

And don't run out of clamps...

[kriskris]

So I learned a valuable lesson in Vacuum bagging. I was helping my friend to buila a board. It was 20kg foam that he hand laminated with 4 or 6 oz.glass/epoxy layer. Once it cured he proceeded to vacuum bag deck with carbon fiber twill. Full vacuum at 28. It still uniformly crushed the board on deck and indented bottom especially where breather was bunched up
What is the safe vacuum pressure range for lower desity foams 1lbs/foot cube or 20kg/m cube?

[handy]

I do 20kg/m3 with 0.6 bar

[kriskris]

Thanks for the info. Will try 0.6 next time! What lay up do you recommend with this foam for pocket foilboard Handy?

[bay surfer]

Decided I needed a pocket board for a new large floaty wing I made. XPS foam, cedar stringers, 110cm by 46cm so far pressed some 6 oz carbon on top and for pads. Plan for the bottom carbon down bottom and one layer around box. Planning on glassing top and bottom with 2 layers of 6oz glass which will be wet sanded and painted (no hot coat). Question is it overkill?