Just wanted to say thanks to everyone for all the great info posted here and beyond. I gleaned enough to tackle my first attempt at a large cruising twin tip. I'm a beginner, kiting in junk Colorado mountain wind, but totally stoked-
Check out what I came up with and provide any feedback/suggestions for improvement. I'm thinking about a foam-core thruster next round.
150cm x 45cm, maybe 3mm rocker, no concave, straight rails, slightly tapered tips, 10cm heelside fins. Straps and pads scavenged from an old windsurf board, materials $60 plus 20 hours labor.
2 coats US Composites 635 Epoxy
Graphics: plain bond computer-printed double-thumbed gonzo fist (Freak Power in '08!)
3/8" Baltic Birch Core
3 oz. glass
3 coats epoxy w/ blue pgment
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Ride report: I've been out on this board three times now. First of all it hasn't snapped in half under my 185 lbs. It gets me going way easier than my 138cm production board and allows my beginner ass to stay upwind better and in junkier wind. It seems to handle chop fine, but it's 1-2 lbs heavier than the production board, so it takes a little more to get it around. I'm pretty jazzed that it's possible to save $700, build something yourself, then go out and ride it without catastrophic results!