Proper Anointment of the Dually Stubby

The south swell filled in so Marlon and I headed out once I got home from work.  The tide was high again at +1.9'.  The wind was side shore - it picked up every now and then, but it wasn't chopping up the surface.  Marlon had some awesome rides - slightly overhead on the set waves!!!

Obviously I brought out the Dually Stubby.  It was a hair squirrelly on my first couple of waves (it is a 5'10" after all), but my third wave was a gem!  Green wave takeoff, solid drop and bottom turn up into a lined up wall.  I turned up and back a few times and I popped off the back.  I had a couple more similar waves, but the crowd was making it hard to pick off the best waves (again, this being a 5'10").  On one missed wave, I belly rode the board and without much effort, I made it all the way to the beach.  My last one was similar - just kept prone and rode the wave all the way in - a sign that this board has a good rocker line.  This board has been properly anointed!!!

#17 (Dually Stubby) is Pretty Much Done

I went ahead and sprayed urethane on the top of the Dually Stubby - just short of the tail.

I still need to fill the slight epoxy shrinkage on the leash plug as well as a couple of small divots on the corners of the tail.  I'll line up a few boards that need a little epoxy work and get this knocked out before the next swell shows up (likely this coming weekend).

Dualie Stubby Done

I got the gloss coat (clear glossy polyurethane spray) on the bottom deck this morning.  I used some decals I got from a coworker to label it instead of using spray paint.  I think it looks way cleaner - but we'll see how it holds up to usage.

I also got the dual single fins on.  This thing looks fast just lying there!!!

I put a little more nose rocker into this board so I can take steeper drops - a lesson learned from the asymmetric fish at Chun's.

A long time ago I had an RRD Kiteboard with this same tail configuration.  I could throw that tail right through a roundhouse cutback like a hot knife through butter.  I'm really excited to get this board into some energetic waves to see if I can do similar turns.

I still need to do a tiny bit of work on the top deck - fill in an edge on the lease plug and some rough spots on the tail.  But before I go foiling today, I'll get the epoxy work done so I can spray the remainder of the board before this evening.  I also want to test the durability of the innegra.  This stuff was not that hard to use, but sanding was a bear trying to stay away from the fibers.  If it resists pressures and other abuse, perhaps it'll be worth the extra effort.

A Second Fill Coat on the Stubby

After the 120 sanding, there were enough low spots across the board and some holes around the fin boxes that all needed to be filled - so instead of proceeding to the 180 grit sanding, I put on another fill coat.  2.8 ounces of epoxy and cabosil to make a manageable slurry.

I wasn't able to get the center part of the top deck filled - but arguably it didn't need to - that section is pretty smooth with no divots.

I'll probably cut the leash plug hole and set the plug tonight - that way tomorrow is sanding day.  I'll get everything smoothed out, place the logo decals on, and spray on a urethane coat.  As this build keeps going on, I keep taking slight detours - but the destination is the same - STOKE CITY!!! Almost done with this one - then I'll turn my attention back to the 4'10" that is sitting on the right of the pictures.

Fill Coat on the Top Deck

When I got home, I got to grinding the laps from the top deck lamination.  Lesson learned - the front laps closest to the nose don't need the second cut to shorten the overlap.  Since I've been doing this recently in rapid succession, I've noticed do this produces a gap in the laminate that has to be addressed during rough sanding.  Oh well - next time.

After that I grinded the finboxes down.  I went ahead and set the dual single fins in just to get a preview - WOW!  I am excited for the possibilities of this board!  There were some air bubbles in the finboxes and I went ahead and opened them up with the Dremel so the fill coat epoxy can get in those spaces.

Then I taped off the rail and epoxied the top deck.  I used 5.6 ounces and got the whole board covered.  The next steps include rough sanding (40-80) the top-bottom-rails, drilling a hole for the leash plug, setting the leash plug; grinding the leash plug down, sanding (120-180) everything down, applying the logo stickers (did not laminate this time and I don't want to spray paint this one), getting a light coat of epoxy over the vinyl stickers (top and bottom so two separate runs); sand the cover coat down (120-180), sand the whole board to 320-400, write in the dimensions, spray on a coat of urethane (again separate coats for top and bottom), then outfit the board - place the leash tether, clean up the finboxes, and get a coat of wax on it.  Considering all these remaining steps, I figure I have at least three more days of work, both mornings before going to work and in the evening after I get home.

Glassing the Top Deck

This afternoon, I got home from work a little later than normal, but I changed real quick into garage clothes and got to work on the Stubby.  I grinded the laps as flat as I could get them, and blew the dust off the board.  I then cut the fabric for the top deck - I used a full coverage Innegra layer (actually finished up the 4 yd roll I got), then a 6 oz patch where my feet will hit, and lastly another layer of 6 oz to cover nose to tail.  This is a little heavy, but it's in all the right places and I prefer my boards to be built to take it.

I had Marlon teach Noe how to mix the epoxy and after I just kept rolling the epoxy on.  Pretty uneventful - until the last minute where I thought I'd fill a transition and ended up jacking up the laminate where I'd always be looking at it while paddling.  I was able to fix it (everything is fixable) so the universe is in balance.

I checked on it to make sure there weren't any dry spots on the laminate, and that there weren't any air bubbles.  Tomorrow I'll grind the laps down where they wrap on to the bottom deck, then get a fill coat on to the top deck of the board first thing in the morning.  When I get home, I grind open the finboxes and address any voids in the laminate, followed by the fill coat.  That will lead into the leash plug install later tomorrow night, or first thing Thursday morning, followed by sanding.  Did I mention I hate glassing???

I'll keep plugging away at this board - hopefully there will be waves somewhere this weekend and this thing will be ready to ride.

Glassing the Bottom Deck

Yesterday the kids and I got the bottom deck laminated.  I started by cutting out the fabric - full coverage of innegra and full coverage of 6 ounce cloth.  I folded back the cloth and set the fin boxes.  Then I dragged the kids out and hand Marlon mixing epoxy and Noe working the fin boxes to prevent air bubbles from developing.

Of the two decks, the bottom is always harder because of the fin boxes and the epoxy doesn't have a hard edge to grab on (like the top deck laps do grabbing onto the cured but still rough bottom deck).

The other issue with laminating the bottom deck is the laps often do lift - and that leaves air bubbles under the glass - especially on the tail and nose.  I went back before the epoxy fully cured and pushed down the bubbles (even though they really don't have any where to go since the epoxy has saturated the glass).  This is the first time I'm using innegra, and it is also the first time I'm using resin tint.  Why not - better to keep learning.

Did I mention I hate glassing???

Afternoon Work on the Next Boards

I worked on the new 4'10" foil board yesterday afternoon.  I used the big router to try and open up the slot for the starboard track block.  After a couple of passes, I finished it up with some sandpaper.  After dialing that in, I went ahead and trimmed up some carbon and fiberglass for the bottom of the two openings.  I was postured to pour epoxy, but got a little lazy.

I moved on to the other board and marked out the three fin boxes and also sanded the stubby with 120 and 180 grit sandpaper.

I thought about cutting in the boxes, but I wanted to think about the center box some more - what is in the picture is an 8" box.  I need to bring some potential fins down to line them up - but for a 5'11" board, I'm thinking the 8" box is all I'll need.  8" boxes will be fine for the two dually tracks.

When I do pour epoxy next, it'll be for the reinforcement blocks in the foil board first, then filling some shaping voids in the bottom deck of the stubby.  Then I'll cut in all the finboxes in both boards and then proceed into glassing.

Contemplating the Stubby

Instead of plunging head first into the last two sandings, I spent this afternoon contemplating the nose and tail.  I broke out the board ruler and measured, sanded, measured, sanded and stood back to take a look.

I got it to be mostly symmetrical (I know what I said earlier - but I did say I'd finish this board first before diverging into the realm of total asymmetry) - close enough that the glassing will make up for any differences.

I measured the thickness as it currently stands - 2 5/8".  A little thinner than I was hoping for - not sure at what point it dipped down beneath 2 7/8" - likely while I was cutting with the planer.  Glassing will put a little more thickness back onto the board.  As I am writing all this, I'm also researching the fin placement.  Tomorrow I will sand down the board with 120 and 180, then mark the finboxes and cut them out.  Depending on the rest of the day, I may try and laminate the bottom deck (but will likely wait until Sunday and laminate both this board and the new 4'10").

Stubby Rough Sanding

I dialed in the shape a bit more yesterday - dragon skin on the rails and 60 grit screen all over.

I'm thinking about changing the tail shape.  Right now this should pivot at the corners, but looking at the fin setup I want to put on the board, it might be better to round out the tail.  I need to think about this.  Today I can get the higher grit sanding done, make any adjustments to the tail and cut in the fin boxes - two dual singlefin slots and a third right down the middle so I can use this as a singlefin also.  The current dimensions are hovering at 20" wide and just under 2 3/4" thick.  The argument for keeping the tail as is would be the shorter length - at 5'10"+ I should be able to manhandle the board through any situation - and with the straighter rail line the board will have more speed - hmmm - I need to think about this...

Final Sanding on Marlon's Board and The Stubby Taking Shape

I got home a little later than normal this evening - so surfing was not really an option.  Instead, I broke out the shaping rack and Marlon finished the 180 grit sanding.  He says he wants to paint the board, so the rest is up to him.  I told him to rinse the board with water to remove all the sanded particles - next I'll take him to Home Depot so he can get his paint.

I brought out the Stubby (not sure this name will stick - will have to think some more about this) and used the planer to set in rough rail bands.  After that I used to surform to even out the top and bottom decks.  I was running out of daylight so I called it quits after that.  I did take a good look at the overall board - I keep thinking I want to narrow out the nose so catching bigger waves will not be as difficult, but I'll probably just trim it down as I shape the rails and keep it mostly fuller.  This could actually be a longboard shape just greatly truncated in length.

Now that this board is getting its rough shape, I think I'll be more diligent about working on it - I can do the bottom rail tucked under cut and fair in the rails with dragon skin tomorrow.

Template Transfer and Cutting Out the Board

Inside every blank is a board waiting to emerge.  Here's this board starting the journey.  This stubby with Duo fin setup (plus a center box for single fin outings) should be really fun.

I took stock of how much blank there was in relation to the template.  I went ahead and extended the template on the board by about 3" (since there was room - I need all the help I can get).

This 5'10" fish blank is thick - the jigsaw with a normal blade was not long enough to get through it.  Might as well get started on this - I don't think the COVID-19 restrictions are going to get lifted anytime soon.