Garage Works - 5/18/2026

The projects have been piling up in the garage.  I just haven't been in the mood to tackle some of these (plus it has been warm and humid lately).

I got approached by Tim yesterday - he wanted another single window on his Amundson board.  I actually cut this hole yesterday - I thought I ran out of milled fibers and said I'd get some today.

I did get another container of milled fibers - but when I pulled out the epoxy bottles, I found the existing container of milled fibers....

I got the fill mixed up and placed.

And I had enough material leftover to get some onto Stu's mast repair.

I placed mold release on the fuselage, then added the epoxy.

Hopefully the parts release - if yes, then I'll shape the mast foot and even add more material to make the front section more hydrodynamic.

I'll likely be in the garage again tomorrow evening - trying to get these two projects completed.

Garage Works - 10/20/2025

This was how the conditions looked at the beach on my way home...

I figured I should rest today and take care of some things in the garage.

Knowing the wind is going to get up into the nuking range later this week, I first rigged the stoppers onto the BRM Maliko parawings.  I eventually figured out it was best to just place the stopper on the same loop that holds the bridle lines.  I got all three parawings completed and function checked.

Next, I made adjustments to the harness/leash belt.  I adjusted to locations of the stopper clips and the leash attachment point.

Then I slightly lengthened the harness hook line and placed some heat shrink over the lower part of the line.

I had contemplated placing the hook and slider onto my T9 harness (since I really haven't been winging lately) - but that webbing belt is 1.5" and the slider is a 2"

After that I cooked dinner and set about placing the stickers on No.42.  I also placed a few more pieces of deck pad 

Starboard side -so when I'm taking off or coming down off foil, I have a little more grip to control the board.

Port side

And lastly, I added some more epoxy to the points on the mast-adapter interface that had shown some corrosion. 

I'll try to get an M6 helicoil installation tool in the next day or so - that's pretty much all that's left to do on this repair.

Tomorrow the wind should be better than today - and that theme should continue throughout the week!

Garage Works - 10/19/2025

I got a bunch of work done on this mast repair.

I measured the center points of the holes - three times.

Then I drilled pilot holes and then a series of progressively larger holes.

Checked the hole alignment before enlarging the holes 

Then all three holes were tapped to fit an M6 helicoil

Then a fit check to make sure the alignment is still good.

The M6 helicoil installation tool I have is broken - so I stopped at this point.

I'll grab another tool and get this repair completed.  

Garage Works - 10/15/2025

I did spend a little time dry fitting the M6 helicoils to the holes I cleared on Felipe's mast repair.

Turns out the holes that I had to dig out the sheared bolts were already big enough to accept the helicoil.

I had to clean up the open (third) hole a little bit.

Now it's time to mix up some JB Weld...

Garage Works - 9/28/2025

This morning I used epoxy and aerosil to fill all the remaining voids across No.42

This should laminate well now.

I taped up the tracks and addressed the transition at the end of the track block.  The carbon tape is reinforcement in lieu of a stringer (and it ties in the track to the bottom skin).  I stopped here because the wind was picking up and I had to work on....

Felipe's NoLimitz mast repair.

I finally got the holes large enough to take the bolts without binding.

Now I can fill the holes back in (probably JB Weld), tap in the new helicoils and this should be done.

Prayot got word his warranty replacement mast came in - so that's one less mast I have to fix.

Day Off - Garage Works - 9/25/2025

I charged up the HO battery and even brought the already setup board/FD/foil from yesterday - but with the wind directly onshore and decently strong, I opted to sit today out.

Instead of Foil Drive-ing, I ended getting some ground handling practice with the Flysurfer POW 4.0 and the BRM Maliko 2.9

I ordered a demo POW 4.0 and it arrived today.

And this is the first time I had the BRM Maliko 2.9 out and flying.  I had already changed the bar out, and I've been trying to confirm the bridle mod was already completed (it has).  There wasn't enough wind to get this parawing to pull like it should, but I did get a feel for it (and I really think it is going to be a blast!).

This 4.0 seemed to have the same power distribution as the Maliko 5.1 - will be interesting to see how close they are.  The 5.0 is definitely more powerful than either the POW 4.0 or the Maliko 5.1 - so that is off on it's own.

This parawing changed direction easier than it's bigger sibling.  That means the jibing challenges I was having on the POW 5.0 is the larger size and difference in handling.

I should be able to test drive this in the water on Sunday and find out first hand.

Of note, there were only brake lines leading up the canopy from the bar.  I'll have to see if that is the same as the 5.0

Also happening today - I got some garage time in.

I placed some epoxy and glass bubbles in the seam of No.42

I'll sand the overage tomorrow and get the track block glued into the slot.  That will set up a weekend lamination.

And I got the bolt holes deeper on Felipe's mast repair.  I still can't get the bolts to just drop in, but I'm really close.

Once the bolts can drop in, I'll clean up the holes and place either epoxy/milled fibers, or JB Weld (probably the epoxy).  After that is in place, I'll drill holes for the helicoils, tap the holes and get the helicoils installed.

Just in time to get Prayot's AFS UHM 80cm foil into the garage for repair...

Garage Works - 9/10/2025

I skipped out on beach time today and I spent that time forwarding the two projects I have in the garage.

Dialing in the shape of No.42 was the big one.

Here's the banana board with the details all chased down.

And from the port side.

I'm still toying around with the idea of using a divynicell deck sheet to reduce some additional weight and increase the board deck skin strength.

If I work on the board tomorrow, it'll be cutting out the block slot on the bottom deck and possibly the top deck d-cell sheet.

I also worked on the mast repair Felipe asked if I could do.  I didn't take a picture, but the progress is slow and steady (to prevent any issues)

Mast Repair

I emailed Kyle and he said to use urethane adhesive to fill the cuts after cleaning the frayed material away.

And I did just that.

The repairs went pretty quickly - and I think they turned out well.

I can see and feel the repairs, but I actually like the fact that they are on the mast - just like cool scars!!!!

I'll write more about this in the next post, but I actually think the mast moves through the water better than before.  That probably just me thinking the repairs help shed any potential low pressure points by introducing just enough turbulence.... but who knows???!!!!????

I glad it's fixed!