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Pocket board building

here you can exchange your experience and datas about your home build boards
TomW
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Re: Pocket board building

Postby TomW » Thu Nov 29, 2018 4:21 pm

Bletti wrote:
Thu Nov 29, 2018 3:55 am
Looks good. Great idea. I might look for a damaged blank to shape down for a pocketboard myself. I was thinking of doing a divinicell core but this could be cheaper.

Please post more photos as you build. I'm curious how you'll reinforce the bolt holes and how light it ends up being.
I will. You can also follow on my FB group TW Surfboards.

Foil mount, I've done several ways.
1. Before lamination, drill 20mm dia holes at 90*165 CC. Tape off hole one side and fill with epoxy and chopped fiber. Do it 10mm at a time to avoid exothermic reaction. Once filled, laminate board and drill out holes. Low tech reliable method.
2. 3d printed plugs with holes. Glue in plugs before laminating.
Both of above need through bolts. this is reliable way as there's no hardware in the board to corrode. Best way for garage builders.

I've ordered Big Head M6 SS 316 blind inserts and plan on making 3d printed sleeves for them. Will glue into blank. This will allow me to use M6 bolts from the plate to deck with no bolt heads on the deck. Cleaner. Easier to assemble mast to board.
Risk is corrosion damage to threads in board.

max
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Re: Pocket board building

Postby max » Thu Nov 29, 2018 9:54 pm

TomW wrote:
Thu Nov 29, 2018 4:21 pm

I've ordered Big Head M6 SS 316 blind inserts and plan on making 3d printed sleeves for them. Will glue into blank. This will allow me to use M6 bolts from the plate to deck with no bolt heads on the deck. Cleaner. Easier to assemble mast to board.
Risk is corrosion damage to threads in board.

I have always used the first method Tom mentioned.

Am about to use tracks in a new build to allow adjustment for different foils . . . but I have just purchased some of these (Big Head M6 SS 316 blind inserts) to retro fit to a board i ride to see how they go. Did not bother before but now I have to remove the foil from the board each time (change in car style), I want a slightly less fiddly method to remount the foil.

I hope to have them in the coming week so will comment again soon.

TomW
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Posts: 2757
Joined: Wed Oct 05, 2005 6:43 pm
Kiting since: 2001
Local Beach: Vejbystrand, Habo Ljung, Lomma
Gear: TW Surfboards 5-0
TW Surfboards hydrofoil board 120 and 135
Moses Fluente 550/590 + 330/325 and 633 set
North Mono 7, 9, 12
Ozone Reo 5
Ozone Hyperlink 9mUL, 7m
Flysurfer Sonic 2 13m
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Re: Pocket board building

Postby TomW » Fri Dec 07, 2018 5:59 pm

I bought some big heads. and I've done some sketching of the section and I think you still have to drill out a 20mm diameter hole, plug it with epoxy, then embed the bighead into that plug.
Otherwise you risk pulling the insert through the top lam buy screw/ compression force.

max
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Re: Pocket board building

Postby max » Fri Dec 07, 2018 10:43 pm

my inserts are 23mm head and 15mm length collars. As I already had 25mm diameter resin plugs, with 6.5mm holes drilled for the 6mm bolts i had been using . . . I simply redrilled to the size to fit the collar, and recessed the big head also to be flush with the top (and the collar end was also flush with the bottom . . . perfect size insert for my current board) and then glassed over the big head.

One use including jumping . . . and all seems well.

Tom . . . what size Big head inserts did you get?

TomW
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Posts: 2757
Joined: Wed Oct 05, 2005 6:43 pm
Kiting since: 2001
Local Beach: Vejbystrand, Habo Ljung, Lomma
Gear: TW Surfboards 5-0
TW Surfboards hydrofoil board 120 and 135
Moses Fluente 550/590 + 330/325 and 633 set
North Mono 7, 9, 12
Ozone Reo 5
Ozone Hyperlink 9mUL, 7m
Flysurfer Sonic 2 13m
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Re: Pocket board building

Postby TomW » Sat Dec 08, 2018 12:07 pm

Same size. M6- 23*15

TomW
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Posts: 2757
Joined: Wed Oct 05, 2005 6:43 pm
Kiting since: 2001
Local Beach: Vejbystrand, Habo Ljung, Lomma
Gear: TW Surfboards 5-0
TW Surfboards hydrofoil board 120 and 135
Moses Fluente 550/590 + 330/325 and 633 set
North Mono 7, 9, 12
Ozone Reo 5
Ozone Hyperlink 9mUL, 7m
Flysurfer Sonic 2 13m
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Re: Pocket board building

Postby TomW » Sun Dec 09, 2018 3:02 pm

PhotoGrid_1544364001912.jpg
Some progress before a business trip. Working on 2 of them. One is 105, this one 90 cm.

max
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Re: Pocket board building

Postby max » Mon Dec 10, 2018 3:10 am

The rocker looks great.

I gather your divinycell does not go through to the deck . . . any ideas on how you will put the inserts in?

TomW
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Posts: 2757
Joined: Wed Oct 05, 2005 6:43 pm
Kiting since: 2001
Local Beach: Vejbystrand, Habo Ljung, Lomma
Gear: TW Surfboards 5-0
TW Surfboards hydrofoil board 120 and 135
Moses Fluente 550/590 + 330/325 and 633 set
North Mono 7, 9, 12
Ozone Reo 5
Ozone Hyperlink 9mUL, 7m
Flysurfer Sonic 2 13m
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Re: Pocket board building

Postby TomW » Mon Dec 10, 2018 1:18 pm

max wrote:
Mon Dec 10, 2018 3:10 am
The rocker looks great.

I gather your divinycell does not go through to the deck . . . any ideas on how you will put the inserts in?
I put divinycell on both sides. So it's bottom to deck. Epoxy with glass fiber mix as plugs. I'll drill out 7mm for bolts. Then 10mm *15mm for collar, and 23mm*2 mm for big head. Then I'll laminate.

I even put a couple layers 6oz glass on bottom of Divinycell patches.

I tried some 3D printed SLA epoxy plugs, but they are too brittle/ expensive material. Testing some carbon + petg filament in the Fdm printer to see if they are durable enough. If it works it will be lighter and easier to install. Small test print was promising.

max
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Re: Pocket board building

Postby max » Mon Dec 10, 2018 11:02 pm

TomW wrote:
Mon Dec 10, 2018 1:18 pm

I put divinycell on both sides. So it's bottom to deck. Epoxy with glass fiber mix as plugs. I'll drill out 7mm for bolts. Then 10mm *15mm for collar, and 23mm*2 mm for big head. Then I'll laminate.

I even put a couple layers 6oz glass on bottom of Divinycell patches.

I tried some 3D printed SLA epoxy plugs, but they are too brittle/ expensive material. Testing some carbon + petg filament in the Fdm printer to see if they are durable enough. If it works it will be lighter and easier to install. Small test print was promising.
I always run the divinycell from top to bottom also but as one large piece (probably overkill).

Is your deck parallel to the bottom?


If i understand you correctly, your collar will not go all the way to the bottom of the board but rather you will have a 7mm hole for the 6mm bolt to go into (a short distance) before it finds the collar.

My new board is about 30mm thick at the tail so have been thinking that there are two ways in which I could approach the installation.

One way like above or another that would put the collar flush with the bottom.

Which do you think would be better?

TomW
Very Frequent Poster
Posts: 2757
Joined: Wed Oct 05, 2005 6:43 pm
Kiting since: 2001
Local Beach: Vejbystrand, Habo Ljung, Lomma
Gear: TW Surfboards 5-0
TW Surfboards hydrofoil board 120 and 135
Moses Fluente 550/590 + 330/325 and 633 set
North Mono 7, 9, 12
Ozone Reo 5
Ozone Hyperlink 9mUL, 7m
Flysurfer Sonic 2 13m
Brand Affiliation: None
Location: Sweden
Has thanked: 3 times
Been thanked: 14 times

Re: Pocket board building

Postby TomW » Tue Dec 11, 2018 12:14 pm

My previous boards have one big piece of HD foam each side. 15mm thick. Trying more minimal approach.

Board is slightly thicker than 30mm and deck is not parallel to bottom. So there's a little blank foam in the middle.

I'm not sure which method is best. But my bet is putting bighead on deck is better than embedded in epoxy close to the bottom.


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