Pocket foilboard divynicell 80 core Ghetto build tips?

[merl]

I'm wondering about a simple build (no vacuum) pocket board in 80kg 20cm divynicell. What would be the simplest way to go for a noob?

(If the answer is "build it in plywood then that's good too)

[tmcfarla]

I used diviycell 80 for mine and it worked really well. I would probably use a divinycell 60 next time though, as I think 80 is overkill. I did use a giant clothing vacuum bag ($10) with a vacuum cleaner, but I think it would have been fine without.

I used 2 sheets of 1/2 inch (12 mm) d-80 glued together with gorilla glue weighed down with books over a surfboard to form rocker. It lost some of this rocker, so build in extra rocker into your template. I think I roughed up the surfaces before gluing. If I did it again, I would definitely consider thermoforming, but that proved to require more heat than I’d hoped (ie my wife’s hair dryer was not up to the task).

Two layers of carbon on each side, wrapped around rails worked well. If I did it again though, I think a couple wide (maybe 8”) strips of unidirectional carbon on either side, nose to tail, and a couple layers of fiber glass. Carbon is a pain to wrap around rails, and I don’t think it adds anything with such strong foam. Add several extra layers of carbon weave on the bottom layer where your inserts go, maybe add patches of carbon weave on the top where your feet go.

Inserts are tricky the first time, and there are a couple ways of doing it, so I’ll leave it up to you to figure that part out, many guides from people more qualified than me. Use 316 stainless steel though.

End result was very light, close to on par with lighter production carbon boards. And it has been holding up very well for perhaps 50 sessions.

[merl]

Thanks. Useful info. Did you use stringers? That looks tricky unless you stop short of the nose kick.

[tmcfarla]

Thanks. Useful info. Did you use stringers? That looks tricky unless you stop short of the nose kick.

Nope, no stringers. Just strips of unidirectional carbon on each side.

[bacon2109]

i'm on going to built a pocket board, no stringer
it's nice to have a light board, you can use plywood as a pocket board, a bit heavy,
difficult to keep the curve of the board, it may change in time

80kg 20cm divynicell : 20cm(8 inch) of what, wide, thick ?

that's how i will do my build
3 ply of 1/4 inch (6mm) thick divynicell(80Kg/m3), 6oz UD carbon fiber(CF), 4oz fiber glass (FG) for not sanding CF,
per layer(top to button);
FG, lenght wise CF, divynicell, +45 degre CF, divynicell, -45 degre CF, divynicell, lenght wise CF, FG.
- rails; inboard CF , FG.
dont know yet if going to fixe screw position or ajustable, my homemade foil use KFbox at the moment.

[merl]

80kg 20cm divynicell : 20cm(8 inch) of what, wide, thick ?.

I meant 20mm thick. Was thinking of trying to bend with a heat gun. Not sure how hard that is. But I bet the fumes will be nasty...

[thewindego]

You can just bend it after you layup one side. Put plastic on the lam and weigh it down till it cures. Overbend a bit as it won't keep all the bend. Repeat for other side. You can make a good board this way for sure. After both sides lamed do a thick fill with epoxy and microballons which you will sand most of it off back to the glass/carbon. Wetsanding with a wood block and various grades of paper isnt too hard on these small boards.

This my latest 118x45x2cm 2.5kg. Full carbon 19oz vacuum bagged both sides plus uni.

[thewindego]

Also boardcad is handy to make templates and its free.

[downunder]

2.5kg is not that light for 120x45x20 board.

My production 6cm thick board is 2.6 as you see. 120x40
Plus, its a tuttle board, heaps of carbon for strength.

The best ghetto build is to take some board and customize it. Way cheaper than buying a closed cell foam.

Tomorrow I will weight Paulownia planks in that size. Might be lighter.

[thewindego]

What production board is that?

My board is for sure overbuilt with the heavy carbon and dense foam. But I don't worry about it being damaged and sucking water or overheating and delam. With 19oz carbon and 50% resin in laminate plus core weight it is as light as it can be. Probably carbon 11oz would be ok with strategic patches.