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 Post subject: Kite Surfboard Build
PostPosted: Sun Jun 06, 2010 5:21 pm 
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Joined: Thu Apr 15, 2010 10:51 pm
Posts: 37
Started a new build on a surfboard kiteboard. I wanted to use materials that were locally available at your hardware store. I live in southern california and it's possible to get surfboard blanks, but I wanted to try to make a strong and durable board from scratch. Core is EPS. 1/8" plywood parabolic stringers and 1/8" plywood skinned deck and bottom. Not have a vacuum bag I had to get a little creative with how to get the plywood to conform to the curves of the deck and bottom concave. You'll see in the pics that I ended up cutting the 1/8" plywood skins into 16 sections before gluing them to the foam. The rails are pvc and are being epoxied on. I will probably complete the build with one layer 6oz fiberglass on each side. Might be a little more than needed, but it's what I have available, and should make for a very strong board.


Attachments:
File comment: rail epoxied on
photo-8.jpg
photo-8.jpg [ 130.53 KIB | Viewed 3389 times ]
File comment: close up of the wood sections that make up the skinned top and bottom.
photo-9.jpg
photo-9.jpg [ 130.09 KIB | Viewed 3389 times ]
File comment: bottom skin
photo-7.jpg
photo-7.jpg [ 140.88 KIB | Viewed 3389 times ]
File comment: blank and stringer shaped down.
sealed blank with light weight spackle

photo-6.jpg
photo-6.jpg [ 111.79 KIB | Viewed 3389 times ]
photo-5.jpg
photo-5.jpg [ 117.7 KIB | Viewed 3389 times ]
File comment: glued on stringers
photo-4.jpg
photo-4.jpg [ 95.32 KIB | Viewed 3389 times ]
{ SHARE_ON_FACEBOOK } { SHARE_ON_TWITTER } { SHARE_ON_ORKUT } { SHARE_ON_DIGG } { SHARE_ON_MYSPACE } { SHARE_ON_DELICIOUS }
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 Post subject: Re: Kite Surfboard Build
PostPosted: Sun Jun 06, 2010 6:11 pm 
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NICE WORK !!! very time consuming constraction i guess , looks stylish also! :thumb:
how did u form your foam ? hot wire?


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 Post subject: Re: Kite Surfboard Build
PostPosted: Mon Jun 07, 2010 4:32 pm 
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The foam that I used for the blank came in 1.5" sheets. It was easy to bend to the shape of the rocker and glue together. Used part of an extra foam sheet to build up the volume of the blank in the middle.


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 Post subject: Re: Kite Surfboard Build
PostPosted: Fri Jun 11, 2010 11:11 pm 
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Just some updated Pics. Got the rail on. Just needs a little sanding and shaping, and then ready for glassing.


Attachments:
pic2.jpg
pic2.jpg [ 132.63 KIB | Viewed 3181 times ]
pic1.jpg
pic1.jpg [ 138.96 KIB | Viewed 3181 times ]
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 Post subject: Re: Kite Surfboard Build
PostPosted: Sun Jun 27, 2010 9:50 pm 
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Updated pics.
Got the top and bottom layers of fiberglass on. Fins will go on next. The finish line is in sight.


Attachments:
photo11.jpg
photo11.jpg [ 339.56 KIB | Viewed 2938 times ]
photo-10.jpg
photo-10.jpg [ 992.73 KIB | Viewed 2938 times ]
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 Post subject: Re: Kite Surfboard Build
PostPosted: Sat Oct 30, 2010 5:33 pm 
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Joined: Thu Dec 07, 2006 7:04 pm
Posts: 140
Location: Slave Lake, AB Canada
Your board looks great!
What are the measurements of your board? Any online resources you utilized in construction?

Where can I find pvc rails?

thanks


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 Post subject: Re: Kite Surfboard Build
PostPosted: Sat Nov 06, 2010 4:55 am 
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The Board is 5'8" x 21" x 2 1/4". Can't say there are any other online resources for the build. The foam is shaped like any other surfboard. (search on youtube for videos). If i had a vacuum bag, I would have done the wood skins that way. (also search youtube for vacuum bagging)
I got the PVC rails at my local big hardware store (HD), look in the section that has wood trimming. These rails are actually waterproof trim for outdoor applications. It's a quarter round. Use two of them together and you've got a 50/50 rail. You can rough shape the rail to a 60/40 (modern shortboard rail) a Sureform. Make sure if you use lower density foam that you've got a vent plug. If the board gets hot (left in you car on a warm day) and doesn't a a vent plug, the wood skins can delaminate. There needs to be a way for the gasses given off by the low density foam to escape.


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 Post subject: Re: Kite Surfboard Build
PostPosted: Sat Nov 06, 2010 5:11 am 
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Also you might want to check out this link.
http://www.akushaper.com/
Great program to create a surfboard template, and it's free!


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 Post subject: Re: Kite Surfboard Build
PostPosted: Sun Nov 07, 2010 3:12 am 
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Joined: Thu Dec 07, 2006 7:04 pm
Posts: 140
Location: Slave Lake, AB Canada
Thanks a lot!
Super sweet program.

I posted a design im thinking of building in another thread.
Have you tried out your board yet? / Any performance feedback on it yet?


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 Post subject: Re: Kite Surfboard Build
PostPosted: Sun Nov 07, 2010 4:49 pm 
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Board rides great, although I'm probably a little bias, as I built it. The board came out a little heavy when you compare it to a regular surfboard. Not such a bad thing, i think it helps it cut through the chop. If anyone is planning on doing this type of construction, I would suggest using a higher density foam. 1.5-2.0 lbs/sq ft. The foam i used was probably closer to 0.5 lbs/sq ft. The light density foam does not have the compression strength needed for Kiting IMO. I've got a couple of spots that have started to delam a little bit. It might just be my construction method. Maybe if i use a vacuum bag I would have gotten a better lamination between the wood skins and foam.


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