Garage Works - 10/10/2024

Yesterday I spent some time in the garage getting this project further towards the finish line.

I sanded the excess fill coat epoxy and got it super close to the finish depth.

Here's the bottom deck-

And here's the top deck

Then I opened up the tracks and applied the bottom logos.

After getting some other errands done in the afternoon, I added another layer of clear epoxy to cover the logos and correct any low/high points.

Today I'll lightly sand the rails and the top deck over lay, place the top deck logo on and then add the top deck clear coat.

After that, tomorrow will be more sanding and the plug installations.

Most likely final fine sanding on Sunday, spraying an enamel/acrylic wear coat, then the deck pads.

Getting real close!!!!  

Garage Works - 6/28/2024

When I got home from work, there was some thermal winds swirling around.  I did not want to get tempted to wing, so I waited a bit.  That waiting manifested itself in the garage.

I sanded No.37 through the 40 grit rough sanding.

Here's the top deck -

And here's the bottom deck.

This board sanded down nicely.  I went ahead and got the bottom deck labels on before Marlon and I headed off to get a surf session in.

And after we got settled once we got back, I got 4.9 ounces of straight aluzine brushed on as a sanding layer and protectant of the labels.

Tomorrow after the dawn patrol, I'll get the same done to the top deck.  By the afternoon, I should be able to drill out the holes for the vent and the leash plugs.  

I'll leave the sanding for Sunday to let the epoxy harden up just a bit.

No.23 through the 40 Grit Sanding

The wind was up and down again this afternoon.  Instead of winging, I picked my kids from school and then hit the garage to start sanding No.23

The funny thing is I drag my feet when it comes to sanding, but once I start, I can't stop.

I ended up pretty much getting through the 40 grit sanding.

The OCD in me sees a few spots where I could put another coat of epoxy and fill some small voids.  I'd rather do this in really good natural lighting - so I'm going to wait until tomorrow after work (or at least I'll look everything over and make the determination whether to fill or leave it as is - I could chase these little divots forever if I let myself).

The wind forecast is down again for the upcoming week - looks like I'll have this board finished sanding and outfitted (since there won't be too many distractions).  I might even sand Kalani's board while I'm at it.  The things I do when there is no surf or wind -

Rail Tape Clean Up Top Deck Cover Sheet

This is a late post - On Monday evening, I placed some 1" carbon tape on the rail to hide the frayed carbon sheeting.  I was able to cover most of the frays so mission success is declared.

And to seal it all up I went ahead and put a 2 ounce fiberglass cover sheet over the top and down around the rails.

I haven't touched it since Monday (too much wind...)

Garage Works Sign

I've been wanting to do this for some time now.  I finally got around to doing it this past week and I just hung it up yesterday.

This is the corner of my garage where I do most of my epoxy/composite work.  So cool if I do say so myself.

Wide 4'10" Prone Foil Board Inspection

I wanted to clean out all the old wax on the wide 4'10".  This board went into service in November of 2019 - so roughly 16 months of nearly continuous use.

This board (like all the rest I've built) was an experiment in sandwich construction and laminating carbon.  I can recall almost all the dings that are on the board - and each was hard earned.  This board has held up very well for how much it has been used and under the loads it has been exposed to. 

I'm looking forward to more time with this board, but I need to get the 4'6" into rotation - so this one may get a rest (but not today - next post...)

Fill Coat and Both Plugs on the NWFB Top Deck

After we got home from surfing, I did some final preps on the top deck and got the top deck fill coat on.  I also got the vent plug and the leash cup holes drilled and the plugs set.

After that La, Noe and I ran several errands.  What I forgot to do earlier was place the top deck vinyl label in place before placing the epoxy fill coat.  No problem - just took a while to sand down, apply the label then re-epoxy.  Tomorrow I'll trim the innegra, place layers of aerosil/epoxy to fill, and then start the final sanding.  This board is almost done.

Garage Produced Rear Stabilizers Batch 3

Yesterday afternoon I got the rough shaping done on the latest batch of rear stabilizers.

I am going to get an M6 tap so I can adapt these to other systems (Armstrong).  Still need to fine sand, then wet sand, then measure out the center line, and set these up for bottom mounts.

Winging Session 6 and the Anointment of No.19

Today's forecast called for steady tradewinds in the 10 to 20 mph range.  I finished work early today and was heading home to pickup Noe to take her to sailing - but the class got canceled due to stronger winds.  She blamed the new students lack of skills - which is true - and then started to look for something else to do.  I stuck to my plan and headed to Hickam to try out the new board.

I setup pretty quick since No.19 fits in the truck bed with the foil bolted on.  The wind seemed a little light and coming from the NE.  Every now and then it would blow from the E and pick up.  The new board obviously has less volume when compared to the Hypernut, but I distributed what volume it does have to support the actions required to get the board up and going.  I could get up on my knees to start without much issue.  On this board I could also pump onto foil - I wasn't able to do that on the Hypernut.  On the first run out, I was even able to almost complete a foiling tack.  I ended up getting several tacks, but they were all wet tacks.  I even got a few wet jibes.  I just need more practice. I did come in once to pull the foil forward in the tracks - about an inch forward as it was pretty far back.  I think I still need to pull it up a little more to optimize.

I met and talked with Harrison today.  He is the best foiler out at this break.  He was encouraging me to go ahead and venture out into the break.  I told him I want to get better on the turns and I have to get the feel of this new board first - but soon enough.  I'm glad I went ahead and brought this board out!  I'd say it has been properly anointed.  Oh - and Marlon said I am allowed to put stickers on it now.

#19 (Wing Foiling Board) Done!!!

This board is done!  I got the Marine Grip on the bottom deck, and the traction pads on the top.

I'll let this board sit in my garage (autoclave) for the rest of the week to have everything set in place and let the epoxy cure up some more.  This picture below is showing the handle in the bottom - shapers have recently started adding this so you can carry the foil upwind while carrying the wing downwind.

That time will also have me get out on the Hypernut a couple to several more sessions.  If I can tack and jibe on foil, I'll feel more confident dropping down to this board.  We'll see if I can actually get there or if I can wait.

I wanted to point out the difference in the laminate - the weave you see is the innegra layers.  This stuff is supposed to be bullet proof.  We'll see - considering I'll be starting on my knees most if not all the time.  No. #19 all pau!!!!

Dialing In the Sanding - Wing Foiling Board

I passed on going to the beach today - the wing foiling board was summoning me to get some sanding done.  I have been thinking about using the Dremel with the ca.rbide grinding wheel to get rid of the innegra bitter ends - well that worked really well.

I got the leash plugs ground/sanded down, and even the bulk of the board.  Tomorrow I'm going to get one more layer of epoxy/aerosil on the the spots that need it (I want to do it while I've got a lot of sunlight), then on Thursday go through the sanding regime (60-120-180-200-320).  I corrected issues with the logos (high points got sanded down - went back over it with posca pens) so the epoxy will cover those adds.

I'm going to measure out the distances where footstraps would go - just so I know for later on when I'm doing things with this board that require them.  I'm still debating if the vent plug is going in the back (where the leash plug would normally go), or somewhere up front (just forward of the deck pad).  Getting close!!!

Evening Session with Special Guests - 6/8/2020

Marlon didn't like surfing the full high tides the past few days - and with the swell dropping the prospect of going wasn't tickling his itch - so I was going to go solo BUT La and Noe wanted to get out of the house and go walking on the beach!  And they brought the big camera!

The wind was light and there was less chop on the water because of that.  There were two wing foilers out, but the wind pretty much died while they were out (not a fun paddle back in having to pack down a wing). 

The swell had also come down a notch - it was still chest high on the sets, but the norm was waist.  And to no one's surprise, the tide was high at 2.0'.  There were only a handful of people out when we got there, and by the time I finished, I was the only one out - perfect foiling conditions and no one out - you can't pay for that!!!

I had the wide 4'10", the tall mast, the GL180 and the P18W out.  The P18W is the fastest tail wing I have.  Minimal drag and enough tip to tip length to get the lift I want (as I'm 190#s).

I had some fun long waves with a couple of pump back out runs.  I had my fill and called it (didn't want to make La and Noe wait too long).  Being able to generate so much stoke from crap waves like this is such a blessing - I love foil surfing!!!

Sanding and Cleaning on Break Day

My muscles were asking for a break day from surfing, so Marlon and I skipped today.  Instead, I setup the new 4'10" with the longer Go Foil mast, the GL140 front wing, and the Ono Foil W228 rear wing.

I had to sand the pedestal mount to fit the gen 1 mast - it didn't take too long and I probably only took 0.5mm off each side (not the top and bottom) from the interior of the pedestal.  I also sanded the repaired GL140 down to 400 on the bottom. 

I also dialed in the W228 rear wing to sit tighter against the Go Foil pedestal.  It was only a little concentrated sanding, but it made a noticeable difference in the seating.  I set a washer in the rear mounting hole (similar to the setup I have on the shorter mast).

When I take it out next (likely tomorrow), I know I'll have to make adjustments.  Besides the #3 screwdriver, I'll bring the 400 grit sandpaper and fair in the top and front.  I'll try and dig up some 800 and 1000 also to get the wing really smooth.

New 4'10" (V2) Outfitted

This morning I epoxied in the vent plug.  I really need to get a 1" hole saw so I don't have to put in more epoxy.  After it set I drilled down the vent hole to open it up to the stringer, then I drilled sideways to make sure the blank was accessible - black boards heat up fast.

You can see the Creatures of Leisure pads on the board - I'm using this board as an opportunity to evaluate a different brand as the backfoot arch on the Dakine Wideload on the 4'10" seems to be breaking down already.  I also wanted to find a front foot pad that doesn't tear up my chest if I'm paddling without a rash guard - more testing.

After the vent was set up, I went ahead and started applying the top deck Marine Grip.  I just used three 2" x 12" strips.  I have the 4'6" beside the new 4'10" for comparison and reference.

I moved on to the bottom deck.  Signed, dimensioned, numbered, and time stamped with a white Posca pen.  I sprayed a clear coat over the writing and then placed the Marine Grip on the bottom.  I opted for 4 of the hexagons and a small 3" stub.  Each of the foilboards I've made are all different - the Marine Grip layout is specific to the board.  Lastly (but not pictured) I dropped in the track bolts.

I'm going to wait another day to bolt on a foil and paddle this one out.  Time is your friend with epoxy.  I'll wax it up the day I take it out, just to give the clear coat more time to harden.  I can't wait to see how this board rides!

Evening Session - 5/29/2020

Marlon came with me this evening, but he didn't surf - he didn't want to over extend himself as he just had his wisdom teeth pulled.  The swell was waist high for the most part, but chest high surf would roll in from time to time.  The tide was a rising high going to 1.6', but while I was out it was at least above 1.0'.  I had a couple of "love" taps from the reef - I didn't notice any damage so no foul.  The wind was up, but it only was an issue when I was trying to go right - got under the board and made for a slower ride.

This was the first day I foiled in a few, so I had to shake a little rust off.  Had some good takeoffs and a few long rides.

The GL140 did not fail me.  Better for the takeoffs that were present, but the GL180 would have made for much longer rides and some wave connections (I did get one with the GL140 today).

Marlon heard from someone on the beach that White Plains is supposed to open on June 1st.  That will help spread the crowd around again.  Funny thing is I might not want to go back (because I really like this place).

Almost Done with #18

I sanded the leash plug cup down this afternoon and I sprayed the clear coat on the bottom deck.  I left it to dry while we went out for dinner.  While we were out, I found a Creatures of Leisure "Eugene" pad (wider) so I'll put a Creatures front foot pad on this board.

When we got back I went ahead and sprayed the top deck with clear coat.  I'll let it dry overnight and finish outfitting the board tomorrow.  I still have to drill a hole for the air vent - going to put this one between the front and back pads since my earlier mess up (epoxy burn voids) are still in this area.  After that epoxy sets, I'll put the dimensions on the bottom deck (4'10" x 20" x 4 3/8"), sign it, spray some clear coat over that, put the deck pads on, string up the the leash line, stick on the Marine Grip patches and lastly put a coat of wax on the nose (to help during takeoffs - remember this board is only 4'10" - every inch is used).  With the completion of this particular board, I can really make comparisons of what properties work best for which conditions.  EPS vs Polyurethane blanks, narrower vs wider, thicker or thinner, more or less equal volume distribution - this is going to be a fun summer!

I anticipate this board being able to catch waves nearly as well as the V1 4'10" - but I am thinking it'll be a tad harder.  This new board is narrower, thicker and lighter - lighter by a wide margin - so it won't have the momentum that the V1 has.  But the flip side is the V2 has way less swing weight so turning should be better, the mass has been driven back so the foil will respond better (better pumping, better control while up on foil), and lastly it should float me better (so despite the lesser momentum during paddling, it'll still paddle easier and I can just outright catch the wave faster).  All theories to be tested soon!!! 

Evening Session - 5/25/2020

Marlon and I waited until 5pm to surf.  It was worth the wait - super light wind made for very easy wave catching conditions.  The swell was chest high with a few bigger sets every now and then.  And the tide was high at 1.9'.  Marlon brought out the GoPro board mount and the mouth mount.  I got him to tail me on an inside wave - fun pictures!  These pictures were all from the same wave.  I nabbed some from the outside that had some really fun drops - some GL140 magic!!!  No breaching - lots of speed runs and some hard turns - can't really ask for more.

And he had some great takeoffs, even though the GoPro seems to magically shrink the wave size and blow up bellies.

Really fun day of surf!