Garage Works - 6/23/2025

I didn't feel like hitting the beach this afternoon... all that paddling yesterday kinda spoiled it for me.  So I decided to make a big push on No.41 

I got the rough sanding finished and noted that there were a few spots that needed some fill - the transom and the walls of the trench in addition to those on the bottom deck. 

Slow and steady, with light pressure when using the random orbital sander makes for great results. 

 The sanding looks really good - but there's more to be done.

I just got in from placing the fill in the trench walls.

I used aerosil and milled fibers to get the epoxy to thicken (so it would hold on the vertical walls).  And I got the low spots on the bottom deck filled with another coat of epoxy.

After sanding, I'll get the plugs installed (and I'll likely go surf tomorrow).  So that leaves sanding the plugs on Wednesday and getting the 2K clear coat on.  Thursday I'll get the deck pads on and then No.41 will be finished!

Whew!

Chop Shop Fest - 1850 to 1600, 1550 to 1475

After Marlon and I got home, and after we ate lunch, I headed out to the garage to cut down the two foils I had prepared the other night.  I started with the 1550 (since this is the third one I've chopped).  I got lucky as heck - no foam exposed on the cut line, or even on the refoiled sections (that has never happened on any of the previous chops).

I nailed this one!

Next I headed into uncharted territory - chopping the HS1850.  I got lucky twice in a row - no foam core exposed during the cut, or even in the refoiling.

This wing looks so much better than the original.  Truth be known, the inspiration for this was the specifications on the new upcoming HS1550v2.  It is only 2 mm shorter in wingspan than the HS1850.  That means the chord was the target change.  Like I had posted before, I figured the new surface area is right around 1600 cm2.

These both came out really nice!  I still need to sand the higher grits, wet sand, re-label and then clear coat these before I can use them.

I still see a place for the HS1850 (especially for winging lighter days), but I can't wait to try out this Chopped HS1600 and the Chopped HS1475!

Chop Shop Uni 300

I've been hitting the bottom lately with this Uni 300 rear stabilizer.  Instead of just filling/sanding it, I decided to go ahead and cut the tips down.  At full size, this rear stabilizer has a lot of stability and lift.  Cutting down the tips while keeping the chord width should loosen up the ride without losing the lift (which helps with not having to pump all the time).  Here's the paper template and the outline transferred to the rear stabilizer.

I used a dremel to cut the bulk off.  Then I used the bench sander to get it rough shaped.  Then I used the sander to fair in the cuts so the foil blends in, and to get it close to the finished shape and thickness.

I cut into the core layer - exposing a layer of kevlar.  I'll mix up some epoxy and fill the cuts and scratches.  Then I'll have to sand again to thin everything out.

Not too bad.  I plan on using this rear stabilizer for surfing and ripping turns!

Fill Coat and Sanding

I got both fill coats on yesterday evening - pretty uneventful, but I could tell there would be some low points and highs to deal with during samding.

And this evening I got the 60-80-120 sanding done.  For the 60 I used the grinder in sander mode.  I should have used the Milwaukee since it has speed control.  For the 80 and 120 passes I used the trusty random orbital sander.  HOLY CRAP - WHERE DID MY HAIR GO????

I'm going to have to place another fill coat to "correct" some of the deeper cuts from the grinder, and to fill in the "lows" that remained after sanding.  There are also some voids along the finboxes that I should open up and fill.  I'll do all this tomorrow after work (get the fill coat on.

After that and the subsequent sanding, I'll end up spray painting the top deck of the board for protection from the sun, fixing the labels, coating with clear coat, installing the leash plug, sticking on the rear foot deck pad and calling it good.

Here's where I left off today.

Labor Day Weekend Work on the Foils

I didn't get as far along as I had wanted to - lots of surfing and other events (time well spent), as well as some pretty humid days (I don't like placing epoxy in high humidity), but I did get some time in to the kite foil.

Two separate sessions sanding away with the random orbital sander - I was able to finish two fuselages and a main wing.

The kids couldn't tell the difference between the original parts and the ones I replicated.

Now to get these put together and out in the ocean -

Bench Sander and Scroll Saw Day

Yesterday afternoon I put in more time to getting pieces and parts lined up.  I used the bench sander to get the kitefoil front wing and two fuselages roughed in.

I tried sanding down the reinforcement blocks (for the mast tracks) with the bench sander, but it was taking longer than I wanted.  I cleared the scrolled saw (serves as a garage shelf when not in immediate use) and set it up to trim the blocks.  It worked perfectly!

Next steps here (as this now makes 5 concurrent projects) are using the random orbital sander to fair in the foil parts, and using the plunge router to clear a void for the mast track boxes to fit in.

Wings Sanded - Mast Glassed Top and Bottom - Base Plate has Bottom Glass

I had some time to work on the foil pieces after work yesterday.  I sanded the wings down first (so I wouldn't be throwing dust into the air on newly glassed work.

And here is the newly glassed work - I got the top laminate on the mast and the bottom laminate on the Base Plate.

Work is going to run long today (Wednesday) so I don't think I'll get much done on the foil this evening.  Maybe I can pour the bead around the mast and clean up the bottom laminate on the base plate.  Or not - we'll see.

Cleaning Up the Fuselage and Mast Bottom Laminates

Back to the work week - sanding, glassing and tweaking the foil is now done after work, after other errands, and before cooking dinner.  Small time window but you know what they say about eating elephants....  Monday evening's tasks - sand down the excess fiberglass from the mast and the fuselage.

And I had Marlon mix up a small batch of epoxy to lay the bead on the two wings.  I should be able to sand the wings down this evening - after watering the plants, loading the electric pressure cooker, cleaning the bathroom....

Cleaning Up the Bottom Laminate on the WIngs

Sunday morning - trimming off the excess with a razor blade.

And sanding down the glass to the finish edge.  I still really like this apron that La made for me - keeps the fiberglass fibers off my skin when sanding.

Next step preparing the base plates (I actually did that on Saturday evening).

More Sanding - Almost Ready to Glass and Assemble

I had some time this afternoon to get more foil part sanding done.  I got the masts done and fine tuned the front wings and the fuselages.

Now all I have to do is sand the mounting plates and I can start mixing epoxy (I think I no longer like that part - and I can feel myself procrastinating already...)

Inching Along - Which is Faster than Before

I spent some time with the Random Orbital Sander and pieces of the upcoming surf foils.

I got the tails and one of the two fuselages tweaked in.  Still need to do a fill on some of the pukas and a finer sanding.  Now that I've gotten past the 50% point in shaping, I am starting to feel compelled to finish.