Grinding Laps and Laminating the Top Deck on the 4'10"

Had to run some errands this afternoon, but I got home in time to work on the board.  Started by grinding down the laps from yesterday's lamination.


Next, I got the bottom laminated.  First I put some carbon down on the dcell patch (2 layers to build up the height of this section - and it was still too low - next time I won't route out so much).  Next I laid down a nose to tail carbon layer (4.8 ounce cloth) and a 4 ounce cap sheet.

Marlon helped again by mixing the epoxy - 4x 5.6 ounce shots.  Got the board all laminated in under an hour.

Next step - grinding down the new laps and fill coat one side.

Laminating the Bottom Deck of the 4'10"

This went surprisingly smooth - thanks to Marlon for mixing the epoxy for me.  4.2 ounces for the two boxes, then 4.9 ounces 3x for the laminating 6.7 ounce carbon sheet + 6.0 ounce E Fiberglass for the fiber.

I'll grind the lap tomorrow and then laminate the top deck.  I'll leave the fin boxes capped this time and grind them open when I take down the fill coat.

For the top deck I'll do another carbon fiber layer and probably two layers of 4 ounce fiberglass (gotta think about this one - could go one 6 ounce plus one 4 ounce also).

Latest Progress on the 4'10" - 28 October

I was going to cut the finbox slots and glass the bottom deck, but La thought I should narrow up the front of the board (CODE FOR SHE DINGED THE BOARD).

I thought I was going to have to glue on a piece of foam and reshape, but I figured I could just sand the blank down some more.

After I fixed the ding, I still cut out the fin box slots.  This was actually the first time I was able to cut the box slots without any issues (my three previous uses had some minor alignments - nothing unrecoverable, but getting it right just feels way better).

Tomorrow I'll epoxy in the boxes and laminate the bottom carbon and fiberglass layers.

Sunday Evening Session - 27 October

Marlon and I hit the surf during the afternoon high tide.  It was 1.5' at 3:30pm, some light tradewinds, minimal swell - smallest day yet this three day spell.  At the end of the session, there were some larger bumps showing up (front runners of the Tasman Sea swell???), but for the most part it was really small.  If I could catch the wave, the Armstrong CF1600 delivered rides all the way to the beach.  I paddled back out with the board inverted just to make sure I didn't hit bottom (even though I did once while waiting for waves - no noticeable damage).

Marlon was catching a few - and he even ended up talking to the cutest girl out there (she paddled up to him!).

The slightly bigger swell kept me out (I think the cute girl kept Marlon out) - but the sunset was really the best part.

Getting Ready to Cut Out the Finbox Slots (for the Mast Track)

I sanded down some of the hardened epoxy high points (so laying the carbon fiber and fiberglass will be easier).

Then I measured out where the boxes will go - 90mm spread.

I'll make the cut tomorrow morning when there is natural sunlight (measure twice in good light - cut once).

Saturday High Tide Foiling - 26 October

I presented at the Lacy Veach Day of Discovery event earlier today - Noe had a regatta, and La and Marlon went to find a penguin suit (Marlon outgrew his old performance coat and slacks) - so after the event I came home and took a nap.  Then I woke up and remembered the high tide was at 2:41 pm peaking at 1.7'.  Everyone was still out so I drove out (holding my breath that it wasn't flat) - there was some energy - but you could barely call it knee high.  The wind was Easterly at 10 mph or so (side onshore at WPB).

I was still able to catch these waves and got several long rides to shore.  And as a bonus, with the CF1600 I was not even pumping - just making small corrections to stay with the bump, then turning when there was a surfer waiting for something they could ride or when the bump looked better the other way.

The 5'6" is just like a longboard (on foil scale).  Definitely a keeper (although if the filleted rails that I'm putting on the 4'10" work there, I may make a 5'4" with the new rail and that can be the all arounder).

I would have been completely frustrated longboarding on a day like this.  With the foil, this is still makeable even totally fun - I love foiling!!!

Seating the Reinforcement Blocks (for the Mast Track Finboxes)

I got these in place last night.  Not too much drama.

Straight epoxy with a layer of carbon on the bottom.  Epoxy mixed with milled fibers spread on the sides of the blocks - then inserted in the holes.

Epoxy mixed with cabosil to fill in the gaps across the top and in the sides of the blocks.

Next is routing out the slots for the boxes.

Thursday Tiny Surf Foiling - 24 October

The forecast said the South Shore surf was going to be really small for the foreseeable future, but that there was some leftover residual energy still lingering today.  I figured I should grab a few while they are still around.

The forecasters weren't kidding.  Maybe thigh high on the sets.  Super light southerly wind flow.  Dropping tide - probably 1.5' and dropping fast when I was out there between 3:30 and 4:30 pm.

I did pick up several waves - all I needed was a small concave section that didn't have a flat spot in front of it and off I went.  After I caught the wave, it was like any other time - milking energy from unbroken sections of the wave.  Of the eight or so I caught, I was able to take five of them to shore.  I mitigated touching bottom on the paddle outs by just paddling the board upside down.

I had fun and I think I've found the bottom end of the range for this board/foil combo.  Having the 5'6" and all the extra paddling power it has really helped - its the "longboard" equivalent (and the longboarders were even having a hard time catching anything rideable).  If the waves continue to diminish, I'll likely pick up windsurf wave foiling again - shorter drive to Hickam after work than trying to get to North Shore.

Humpday Foiling - 23 October

I caught the back half of the high tide this afternoon.  The trades were up so there was texture on the surface, the swell was almost waist high and the tide started at a peak of 2.1' (when I got there it was probably closer to 1.6' and dropping fast).  Perfect conditions for foiling on the Armstrong CF1600!  I probably caught 8 waves in the short time I was out - all but one were long gliding rides from the initial break all the way in.  The one I botched the takeoff - you have to do this every now and then to keep the arrogance in check right???  I nailed all my turns today and did I mention the glide???  Sooooooooo nice!

I did not chance hitting the bottom on the paddles back out - always paddled the board back out with the foil pointed up (upside down rig).  I used the trusty 5'6" and had the FCS leash out.  This leash was behaving today.  There were several longboarders out - some really good regulars that have total knowledge of this break - but on a foil, I was getting super long rides.  I really think I'm done with surfing (unless it gets over head - then I'm definitely surfing; but chest and below there is no comparison).

It's Been a Really Long Time...

- Since I've used a vacuum bag in surfcraft construction.  Yesterday evening I got back on this horse.  Prepping is everything with this technique.

Here's the board under vacuum.

A few hours later - it came out of the bag all cured up.  The press got the dcell on nice and tight, but the 6oz and 4oz layers I placed beneath the dcell were not thick enough to make up for the depth I routed out.  I'll put in an extra layer or two of carbon fiber before I laminate the top deck with fiberglass.  Next will be getting the dcell blocks set for the mast track/finboxes.

You Know You Have It Bad When...

You are constantly checking the tables for optimum conditions and you plan the rest of your life around the tide -

Vacuum Tank and Fittings

I got the tank (for extra volume and to serve as a sump if epoxy ever did get into the line) all glued up and the fittings installed.

I just need to get some more vacuum pump oil and I'm ready to bag the 4'10"

Furthering the 4'10"

Did some fine sanding.

Also routed out the area where my front foot will most likely land for the divynicell sheeting (I'm doing this because I can't stand pressure dings).  I'm going to finish off the vacuum press also.

Almost time to bag!!!

Sunday Dawn Patrol - 20 October

Marlon and I hit the beach at first light on Sunday.

The wind was light, the swell was up (chin high on the sets, if not higher) and tide was headed to a high of 2.0'.  Same equipment as the last few times.

I paddled out to the green waves to see if I could takeoff on these - I wanted to find the upper end of the CF1600's range.  Well - I found it.  The first three waves I took off on I was able to get to my feet, but the speed I was going was a bit much - I got thrown.  If I did make the drop and settle, I ended up breaching.  I figured I should stop beating myself up and stop trying to break my gear by going back towards shore and picking up the waves once they've dissipated some of their raw energy.  After that, I was getting some really long rides and cranking some turns.  I had one turn where the foil dropped out from underneath me again.  After that I tried leaning into the turn and anticipating the extra speed and the turns seemed to get better.  Further in the session, I had a mix of aborts (it got crowded and I had to stop or put the noobs at risk if I messed up the ride) and wipes (green waves again... can't help myself).  At this surf height, I should bolt on the HS1550.

I was using the Takuma coiled leash - I won't be doing that again - I never felt comfortable using it.

This was also the day of the Board Swap at Kalaeloa.  Lots of cool boards!