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chrislandy 03-22-2014 05:26 PM

Was going to buy, now built
After looking around at the boards available and following on from my recent wakeboard weight thread, I decided to build one instead :D

It's still not quite finished but getting there,

1420 x 445 at midpoint, 300 tips
Approx 3kg (6.6lb) but the next one WILL be lighter (aiming for 2.5kg (5.5lb) or lighter)
10mm concave at midpoint, flat tips
late 3 stage hybrid rocker
wrapped rails at the moment but next board will have PU or ABS rails
Full Carbon Fibre & foam construction using UD, Bi-axial & twill weaves
Foam is 6mm (1/4in) Corecell M80 from Gurit, propper marine foam with decent mechancial properties

This is the foam all measured & cut out with indert positions

Layed up and in the vacuum bag, the next board will have a heated cure in the oven. (The resin I use likes a higher temperature cure cycle)

Demouled and first trim but shows the amount of rocker

Edge to edge concave, should edge well but expect it to be quite unforgiving.

Rocker profile, the camera has skewed the angles a bit as it looks a little squashed

The basic board, first trim done but needs a bit of work to get a decent finish

The concave is quite high so I'm going to have to lay up some extra over the heal/toe of the bindings to ensure it's flat.

Thats it so far :) once I've done some more work on it and taken it out for a ride, I'll post up the results

snork 03-22-2014 06:02 PM

awesome, like to see the progress

thatsmrmastercraft 03-22-2014 06:05 PM

Great project.

chrislandy 04-02-2014 06:57 AM

Quick update on progress, the foot pad area has been bonded on

It's now been sanded and shaped ready for the reinforcement to be added over the footpad.

BGcraft 04-02-2014 08:29 AM

Cool stuff cl. Thanks for posting.

JamesL 04-02-2014 08:31 AM

looks like a fun project

hondaprlud 04-02-2014 09:38 AM

what a cool project.

blackhawk 04-02-2014 10:32 AM

Chrislandy - What are you using to cut out your foam pieces?

chrislandy 04-02-2014 10:46 AM

Just a 1.5m metal straight edge and an extreeeeeemly sharpe surgical blade

chrislandy 04-07-2014 08:00 AM

Just need to add the fins now so progress to date:

Footpad reinforcement added (3 layers 200gsm plain woven) and fully vac'ed down:

Board is now laquered but it really shows up the flaws now so I might sand that down and paint it to hide it all with a few choice bits of carbon showing...

The creases in the top sheet are from laying up off the rocker table, applying the vacuum then fixing to the table. I think if it had another "stiff" layer on top of this before mounting it to the table it would stop the fabric from creasing so much, or doing a multiple stage layup and cure. It needed to be done that way because the cut foam strips wouldn't stay aligned properly if laid up on the rocker table. The addition of an opaque topsheet would hide any distortion in the weave too.

It actually looks better in the flesh, the photos seem to have emphasized the flaws unfortunately :( As it's my first board made like this, I'm pretty happy with how it's come out as the astetic wasn't top priority, more proof of concept for the next board :)

Finished weight 3.6kg, so a bit on the dumpy side but I also know where I can take out the weight for next time...

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