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Pocket Board (HF) Layup Question

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jespin4845
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Re: Pocket Board (HF) Layup Question

Postby jespin4845 » Sat Jul 13, 2019 4:51 pm

a picture of the first board that broke,...only 12mm or 1/2" divinycell

something tells me kanaha shapes guy tried 1/2 and broke his also, he makes it at 3/4"

i think i will stick with 1" with my boards unless i make a future palownia one

also a picture of the next board after vacation, shaping got easier and i practiced with a router for the boxes and also the rails...also helps tremendously to computer generate a template with the middle line and have it on there from the get go

i drew an outline of a fin box, scanned it, went into paint, spaced them perfectly then printed it out,...put it on the divinycell and traced, then routed out very carefully as i don't want to buy a futures jig for $200

the f*** ups around the fin box will be filled with cabosil/epoxy anyways
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jespin4845
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Re: Pocket Board (HF) Layup Question

Postby jespin4845 » Sat Jul 13, 2019 5:08 pm

some other things, oversize your peel ply, getting breather off the board that touched epoxy is annoying,

when using a vacuum storage bag, you can pump out some air, massage it flat to reduce the wrinkles, then pump out more air,..massage more...then pump out...etc...less wrinkles, less sanding..

everything gets easier the second time, i must have vacuumed the first board 10 x from f ups...second board 4 times...

a local fiberglass store will sell a 4x8' of divinycell for $130

the carbon is the expensive part cause of the f*** ups you will do...

i did lay up wake skates a year ago with fiberglass, that taught me a lot before this project

teftelja
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Re: Pocket Board (HF) Layup Question

Postby teftelja » Sun Jul 14, 2019 8:10 am

Inspired by this topic, made my own one for the first time. 2 cm Xps core wraped in 200g carbon, then 3 mm airex both sides, then 240g carbon and two patches over the foil plate. Then wraped it in 50g glass with coloured epoxy - colour was bad, so painted it. Board is 95*41 cm and weighs 1890g. Very stiff. Despite of small size handles touchdowns surprisingly good.
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hcohen2018
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Re: Pocket Board (HF) Layup Question

Postby hcohen2018 » Wed Jul 17, 2019 8:28 am

WOWWW so nice to see your boards!

teftelja - how did you go about painting it in terms of inserts? do you paint in between coats? how do you uncover where the insert hole is?
Also, why not just go with 3mm XPS? instead of the multiple layers, is airex makes a real difference?

Great board, I still trying to find the time, at least its Jellyfish season here so I'm not missing out.

teftelja
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Re: Pocket Board (HF) Layup Question

Postby teftelja » Wed Jul 17, 2019 2:58 pm

I dont know exactly if airex make a big difference cause its my first board, but it is much stronger than xps. The whole airex board would be about 200. - 300 grams heavier. I think without high density foam you need to add more layersof carbon/glass.
About inserts - you Just fill nuts with melted candle. They can be easy detected after vaccum bagging, cause they leave visible wells.
Didnt understand your question about painting.

teftelja
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Re: Pocket Board (HF) Layup Question

Postby teftelja » Wed Jul 17, 2019 3:04 pm

I Will make one more board next week for my friend. So can make photos with description for the whole process.
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hcohen2018
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Re: Pocket Board (HF) Layup Question

Postby hcohen2018 » Thu Jul 18, 2019 6:04 am

Thanks. I'll probably won't use airex ( or equivalent pvc sheet). But my mast connection will be reinforced with Pauwlonia wood and a big g10 plate and also two stringers, I hope to start next week (kids, job, jellyfish, life... :) )
It might be an overkill but I'm a heavy guy.

teftelja
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Re: Pocket Board (HF) Layup Question

Postby teftelja » Thu Jul 18, 2019 12:00 pm

I am not lightweght too - 92kg. Big g10 plate Will weigh t much. But everything is about price. My board cost me 200 USD for materials.

TomW
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Re: Pocket Board (HF) Layup Question

Postby TomW » Fri Jul 19, 2019 10:16 pm

The airex is probably 80kg/m3 and the way he did it with carbon under and over creates strong sandwich layer. This is right way to do it.
The xps is like 20kg/m3 and super soft, and would require many more layers of laminate to achieve level of sandwiche strength.
When putting patches for foil plate area you should always have the same patches top and bottom. One sided laminate doesn't do much but increase impact strength of the area.
You probably didn't need the airex on the bottom, but it's increasing stiffness and breaking strength a lot.
Just think of the idea that you are making a cantilevered beam.
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hcohen2018
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Re: Pocket Board (HF) Layup Question

Postby hcohen2018 » Mon Jul 22, 2019 6:09 am

Was able to start yesterday, I can only continue working in two weeks so updates will be slow :)
The g10 plate is 17x30x0.2cm so I don't know if the weight penalty is that big, I'll weigh it and update, the idea to add some real strength at the mast plate area.

stringers and mast area are made out of paulownia (wow, first time working with it) so very light.

Rocker is by kerfing, hope to get something like 7cm.

Its going to be a wide board, I'm a bigfoot (14US/49EU) so basically put my running shoes and on top and decided --> 118*51, going to 44 at the tail.

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