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 Post subject: My New Year board build!
PostPosted: Tue Jan 06, 2015 3:46 am 
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Joined: Mon Jul 01, 2013 7:16 am
Posts: 352
Location: Perth, Australia
Being busy :)

Decided to build one small board for me, let's say 120cm :) A previous one was sold and I'm craving for the same board. Small, fast and responsive. Board off's here I come:)

Instead of using a bamboo as a core, this time went for full Paulownia deck 1cm thick.

Making a plank:

Attachment:
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DSC01096 (Small).JPG [ 98.76 KIB | Viewed 1021 times ]


Paulownia is quite soft and drilling it for the SS inserts can rip the wood off, hence nice colored plugs 2mm thick (premade), on top of insert holes. Fins inserts premade. Rails premade.

Attachment:
DSC02389 (Small).JPG
DSC02389 (Small).JPG [ 89.48 KIB | Viewed 1021 times ]


A lot of sanding and a router work (thinning tips to 3mm), but it has come pretty well :)

This is the top. Bottom not finished yet.

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DSC02390 (Small).JPG [ 153.77 KIB | Viewed 1021 times ]


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DSC02391 (Small).JPG [ 157.31 KIB | Viewed 1021 times ]


Very rigid in the middle with soft tips to outer footpads. Used 200x2 200g UD FG and Carbon UD tape, with 200g epoxy (for top only). Springback 50% - rocker table set on 7cm.

Keeps rocker very well, 3cm, 5mm concave in the middle only.

Thinking to use some light FG for bottom unless I decide to build a concrete block:)

Enjoy

As before, follow me @http://www.facebook.com/ShinaiBoards

downunder

PS
Was glassing this board yesterday on 44.4C ! The board itself was 40C for hours!

Target weight is 1800 grams :)


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 Post subject: Re: My New Year board build!
PostPosted: Thu Jan 08, 2015 8:52 am 
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Joined: Mon Jul 01, 2013 7:16 am
Posts: 352
Location: Perth, Australia
Light as feather :)

At the end, it is way lighter, this weight is with mounted fins!

Attachment:
DSC02405 (Small).JPG
DSC02405 (Small).JPG [ 139.62 KIB | Viewed 895 times ]


The board is beautiful, and I really don't know how to top this :)

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DSC02394 (Small).JPG [ 117.33 KIB | Viewed 895 times ]


Covered SS inserts with a bamboo veneer:

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DSC02395 (Small).JPG [ 111.31 KIB | Viewed 895 times ]


PU rails exposed on tips 3mm:

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DSC02397 (Small).JPG [ 110.45 KIB | Viewed 895 times ]


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DSC02396 (Small).JPG [ 83.99 KIB | Viewed 895 times ]


This time went for mat, not a shiny surface (no varnish), and feels like 300 sand paper. On touch feels like rough surface:


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DSC02404 (Small).JPG [ 98.71 KIB | Viewed 895 times ]


Awesome of awesomeness :)

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DSC02401 (Small).JPG [ 115.26 KIB | Viewed 895 times ]


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DSC02402 (Small).JPG [ 138.66 KIB | Viewed 895 times ]


And rounded rails in the middle!

Now the test: how is going to ride?! :)

Report soon...Any questions are welcome!


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 Post subject: Re: My New Year board build!
PostPosted: Thu Jan 08, 2015 12:15 pm 
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Joined: Mon Jun 07, 2004 8:44 am
Posts: 157
beautifull! if only i had the skills 8)


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 Post subject: Re: My New Year board build!
PostPosted: Thu Jan 08, 2015 1:47 pm 
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Joined: Mon Jul 01, 2013 7:16 am
Posts: 352
Location: Perth, Australia
Thanks man!

I did not have any skills or tools before building a first one :) Give it a go!

Cheers

D.


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 Post subject: Re: My New Year board build!
PostPosted: Fri Jan 09, 2015 12:39 am 
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Joined: Sun Oct 06, 2002 1:00 am
Posts: 260
Location: Ryukyu islands, Japan
Very nice! Looks like a fairly simple build by your pics.
With a great result too!

How did you soak up the excess resin? Vac?
How did you get the resin-rails in? Routered and poured? Epox or Poly?
At what point did you set the rocker? before putting in the rails, or after?

We've been experimenting with ply's & paulownia sheets for builds, but it's been hit or miss..
Any advice/answers would make the next build more likely for a 'hit'. :D

Thanks so much for sharing!
Best,
K.


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 Post subject: Re: My New Year board build!
PostPosted: Fri Jan 09, 2015 3:30 am 
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Joined: Mon Jul 01, 2013 7:16 am
Posts: 352
Location: Perth, Australia
Kaito wrote:
Very nice! Looks like a fairly simple build by your pics.
With a great result too!

How did you soak up the excess resin? Vac?
How did you get the resin-rails in? Routered and poured? Epox or Poly?
At what point did you set the rocker? before putting in the rails, or after?

We've been experimenting with ply's & paulownia sheets for builds, but it's been hit or miss..
Any advice/answers would make the next build more likely for a 'hit'. :D

Thanks so much for sharing!
Best,
K.


Thanks

You'll need to look at my Xmas build ( http://www.kiteforum.com/viewtopic.php?f=107&t=2387274), the process is well defined.

First, making a core is not simple and vac is needed for a perfect level of all wood strips (not all strips were the same thickness):

Attachment:
DSC02051 (Small).JPG
DSC02051 (Small).JPG [ 127.06 KIB | Viewed 755 times ]


The above is simple vac table powered with a vac cleaner. Works well.

The rails are put way before everything, and what you can't see here is that wood strips are not glued together all the way. Only lightly on ends. After routing the rails are keeping all in place :)

The idea is to minimise a springback. Because it is one wood layer and not two (top deck), the rocker table is set to 8cm! Hence more than 50% sprinbgack. But I recon it might be even bigger IF all wood was glued in one piece as a core. I do have a core 1cm thick and it is impossible for me to bend it with my hands. That is the biggest problem. Hence I am using thin bamboo + top deck for other builds (but more expensive).

3cm rocker as a result:

Attachment:
DSC02403 (Small).JPG
DSC02403 (Small).JPG [ 106.58 KIB | Viewed 752 times ]



For this board I've used 290ml epoxy, and a bit of PU glue for the rails. Smiling all the way to bank when hearing of 1-1.5L what others do :)

The advice is repetitive work :) Mother of mastering is repetition!


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 Post subject: Re: My New Year board build!
PostPosted: Fri Jan 09, 2015 7:40 am 
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Joined: Mon Sep 03, 2012 12:36 pm
Posts: 555
downunder wrote:
For this board I've used 290ml epoxy, and a bit of PU glue for the rails. Smiling all the way to bank when hearing of 1-1.5L what others do :)


1.8kg!!! Very impressive but f**k me I don't know how you do it!? Do they not snap easily? So what's the total weight of glass going into this board, given that small amount of resin not a lot I would assume?


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 Post subject: Re: My New Year board build!
PostPosted: Fri Jan 09, 2015 8:09 am 
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Joined: Mon Jul 01, 2013 7:16 am
Posts: 352
Location: Perth, Australia
Don't know how much FG really, I think on top is about 300g (FG + carbon), bottom about 70g. But that is before cutting excess as you see there was some. Used UD for top, and biax for bottom.

So it's not 1:1 FG and epoxy. The 5mm bamboo ply did not snap in 2 years, I don't see the reason why this would. But than, I'm light. If it snaps on bottom, will build one with more biax and less UD :naughty:

This is not even premium quality Paulownia, the next one will be!

Cheers


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 Post subject: Re: My New Year board build!
PostPosted: Mon Jan 12, 2015 1:38 am 
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Joined: Sun Oct 06, 2002 1:00 am
Posts: 260
Location: Ryukyu islands, Japan
DU-san,
Checked out your Christmas build too!
Thanks again for sharing your process and pics of your awesome builds!

I'm sourcing all the materials, and should be ready in a couple weeks. ~ Stainless M6 hardware for the strap inserts are harder to find than expected here in Japan...

It's gonna be another 'ghetto build', but its the result that counts!
Will post a few pics once finished.

Domo arigatou~!
K.


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 Post subject: Re: My New Year board build!
PostPosted: Mon Jan 12, 2015 7:57 am 
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Joined: Wed Sep 11, 2013 3:51 pm
Posts: 68
Looks awesome, dude!

How do you know how much springback to expect?


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