Partly inspired by earlier posts of downunder I just did a travel pocket hf board using a bauhaus 800x400 sheet. The idea was to test a low cost minimally reinforced board. It was going to be simple, but in the end I stuck on a bit of high density foam to make a kick-nose which made the build more complicated. 940x400 final size.
The board was vacuum bagged. I made a mess of the cosmetics by running out of the spray paint.
Here is the cost estimate and construction outline
800 x 400 x 18 Paulownia board
EUR 13 (https://www.bauhaus.info/leimholzplatte ... p/14084242
0.3x1m 300g/m2 fiberglass for center reinforcement
EUR 2 (cheap hardware store)
1m2 100g/m2 fiberglass for whole board
EUR 5 (easycomposites.eu)
Epoxy resin 200g
EUR 4 (cheap German stuff from Amazon)
EUR 8 (aliexpress/amazon)
Consumables (peelply, breather, release film, bag)
Not counted: scrap of HD foam for nose, rattle-can paint, PU glue
Final weight 1.9kg including pad. I.e 100g more than crazyflys 99x44 pure pocket board, but Eur1000 cheaper.
I promise to update the post if it breaks!
[Update after first outing] It didn't break
but I did feel like it rode a bit more twitchy than I expected. The only reason for this that I can think of is that it is flexing a bit. If I support the board on its ends and stand my 93kg in one foot in the middle I can feel just a little flex. Not much but a little. Maybe this is enough to make it feel a bit "lively". For comparison my regular boards are 100% carbon on hd foam, with generous uni carbon in the middle, but not so thick (25mm).
If I made it again, I would add an extra staggered layer of reinforcement in the center to stiffen it up a bit more. I might still do this, but it is a pain to take off the tail pad...