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 Post subject: Planning on building my first plywood Door.
PostPosted: Tue Jun 22, 2010 10:23 am 
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Joined: Thu Apr 24, 2008 10:28 am
Posts: 19
Hi..

I'm planning on building my first plywood DOOR similar to this one : www.kiteforum.com/viewtopic.php?f=107&t ... 76#p656276

- Same shape, different size tho.
I'm thinking that i'm gonna build it approx. 146 x 48 or 50 since i'm a big guy.

Looking through the many different posts in here, here is my plan:

- Glueing 3 piesces of 4mm plywood together and giving it a very little rocker.
- Shaping the top 3d and thereby reducing weight and giving it a little more flex.
- Then painting it.
- Then giving it 2 fiberglass mats on top and 3 on the bottom.

How does this plan sound?

I have a few questions that i hope you can help me with:

-When i bend the board a little while glueing it, how much of this bend will dissapear when i remove the weights i put on the the board? Should i bend it more than i need, so that i will aline afterwards? If yes, how much would you guess i should bend it extra?

-Is there any special kind of paint/spraypaint i should use??

-What thickness fiberglass should i use?

- Have i forgotten anything in my plan?

-Should i give my board any kind of waterresistant treatment before painting it?
If yes, what??

I know i have a lot of questions but really hope that some of you boardbuilder "pros" can help me out.
And sorry for my poor english.

Best regards


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 Post subject: Re: Planning on building my first plywood Door.
PostPosted: Tue Jun 22, 2010 1:10 pm 
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Joined: Sat Jul 05, 2003 8:28 am
Posts: 210
Location: NL
My first Door was 3x4mm plywood with varnish. No rocker, no fins and lots of flex. Great board, lots of low end and even high end. But it was very heavy and had lots of spray in choppy water.

So you don't need fiberglass, but if you do use it you can remove parts of the middle layer of plywood and make the board hollow.

You only need a little bit of rocker for comfort and you don't need extra bend.

My second board was made with foam, glass and epoxy with 1mm HPL. Just as good as the plywood board but half the weight and more durable.


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 Post subject: Re: Planning on building my first plywood Door.
PostPosted: Tue Jun 22, 2010 1:33 pm 
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Joined: Thu Apr 24, 2008 10:28 am
Posts: 19
Thanx for the great reply! MUCH appriciated.! :thumb:

I don't mind the weight, this board will only be used in minimal wind - 7m/s or so.

I want to try it out with the fiberglass, at least just to give it a cool finish. :)
- So i'll remove some of the middle plywood to reduce weight. Not to much tho.

If you could answer some of my other questions, i'd REALLY appriciate it.

Thanks bud..


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 Post subject: Re: Planning on building my first plywood Door.
PostPosted: Thu Jul 29, 2010 12:42 am 
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Joined: Wed Jul 28, 2010 1:29 am
Posts: 37
to build a door there are 2 things to do it right first put one half inch side cut in it and second make sure that the widest part is at least 10 inches in at each end otherwise it will splash u most people put to much fiberglass and resin and to much wood ending up with a heavy board u must use resin and about 6oz. glass only one layer because your covering wood about rocker when u glue it u will lose about one half inch not very much please put just a little rocker u will be glad about1 inch


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