Garage Works - 1/29/2026

I got the detail work done this afternoon.

I drilled out the foot strap insert holes (pilot, bigger, biggest).

Then after some deliberating, I got the deck pads on with the holes punched for the foot strap screws. 

I also got the leash plug cleaned out and got the vent installed.

This came out really nice!

I'll let the deck pads sit for at least 24 hours -

I also lined up No.41 (Trench Board) to transfer the AFS Enduro 900 position - this is as good a starting place as any.

Feels good to have this one finished!

Garage Works - 1/27/2026 - Part 2

I went back in to the garage and I got the plugs installed.

Drill pilot, drill hole, fit plugs, tape hole, fill with epoxy, hold in place, remove excess, let harden.

These plugs only need about 0.36 and 0.14 ounces of resin.

I also filled the two spots that were low (and open because of an air bubble).

So tomorrow I'll sand these plugs and fills, open the tracks and spray the clear coat.

Garage Works 3 of 3 - 1/24/2026

Last garage works post for today.

Kalani dropped off his board after his Foil Drive session at WP.  Marlon and I were just getting back from Hapa Surf Shop when he got to the house.

This is the airline vent that the KT board has. 

With the board this dark, sunlight generates a lot of air expansion potential - that's actually how I found the small pinhole leak I fixed when Kalani had me install signal windows.

Here's the retrofit vent kit I got from Fiberglass Hawaii.  With this version, if you are careful, you really don't have to sand the area around the vent.

Here's to vent plug cut out of the board.

Just in case (and since I was going to be away getting lunch) - I placed the fan on the board.

After sanding No.43, I checked the hole to make sure there was no moisture in the foam.  Then I mixed up enough epoxy and aerosil to fill the hole and get squeezed out (making sure there was enough epoxy mix inside the hole).

I cleaned up the edge around the vent plug lip - to make sure this is properly sealed.  I used a mixing stick and used the same technique stick welders use to get an even bead across the work.

I'll drill out the vent hole tomorrow morning, get the vent screwed in, then the board goes back to Kalani.

24 hour turnaround!

Garage Works - 10/7/2025

The surf was tiny and the wind was onshore - I kept to the garage.  Besides, I really need to finish this board so I can get it put through its paces this weekend.

I resanded the patched areas and faired everything in again.  I filed the track box fill (where the router took too much).  Then I wiped the board down and taped up the perimeter.

I used 7.5 ounces of ProLink epoxy for the last fill/seal coat.  I got the rails and the bottom deck coated.

Then after a few hours, the epoxy was pretty much hardened.  I taped up the bottom perimeter and then mixed up another 6 ounces of the Pro Link.  I got the top deck and the rails coated. 

Tomorrow I'll sand the board - top, bottom and rails through the whole regime.  Then I'll get the vent and leash plugs installed.  I'll try to get through all that shortly after I get home from work tomorrow.

Once the epoxy placed in the leash and vent plugs hardens, I'll sand those down and then spray clear coat on the bottom deck and the rails.  This is where I start to question whether I'll have enough time tomorrow...

Ideally I'd then get the top deck sprayed.  Then Thursday morning I'll place the deck pads and let those set for 24 hours.  If I can get all that done in that schedule, the board will be ready for use on Friday.

The forecast is kinda shifting a bit - but Saturday afternoon looks to be the point where the tradewinds return.  So I've got an extra day or so....

And with the crappy conditions, I'm actually getting to rest my body from the nearly non-stop foiling (parawinging and Foil Drive-ing).  I actually need this break!

Update - I headed back to the garage after dinner and got the plugs installed.

Measured out position on the board and drilled out the pilot holes.  Switched to hole saw bits and got the openings drilled in.

Used about 0.2 ounces of epoxy to set these two plugs in place.

Today's work got me ahead of planned schedule.  Wednesday should be sanding and clear coat spraying.  And Thursday will be deck pad application.

The trades look to be solid on Saturday - I'll likely head to Hickam to get the foil positions dialed in on wing, then try parawinging it!!!

Garage Works - 6/24/2025

I came home late and wanted to get out to the beach to get some of this swell - 

So I measured and drilled out the holes for the plugs, then packed for the FD session.

And when I got back I set the plugs in place with epoxy.  0.7 ounces with aerosil for both plugs.

Tomorrow will definitely be sanding and clear coat spray.

Garage Works - 2/9/2025

I got through pretty much all the sanding today.

Here's the bottom deck -

And the top.  When sanding the top, I found a few voids - I kinda expect a few when I do think laminate layers (or innegra).

I figured I should go ahead and fill the voids while installing the plugs.

And here's the work I'll be sanding down tomorrow.  Two plugs and a few fills - should go pretty quick.

After that, I'll open up the tracks and fair in the cuts.  If I have time tomorrow - I'll pick up some of the 2K clear coat and get that sprayed on.

Then I just have to wait for the WMFG deck pad to get in and No.40 will be finished!

Next up - Norm's Code 1130S repair, replacing the tracks on No.32, and converting an older prone board into a modern Foil Drive board.

Garage Works - 12/10/2024

And to keep progress going in the right direction, I drilled the holes for the plugs and got them epoxied into place this evening.

Leash plug - orange on orange.  I've never done that before.

And the vent plug is under the weight.  That's so it wouldn't float on top of the epoxy.

Tomorrow I should be able to sand the plugs down, then sand the entire board, and maybe even get the clear coat sprayed onto the board.

I've still got some sanding to do, but this board is going to end up being on the heavier side of the spectrum.  That is partly due to the footstrap inserts.  And it is also due to the multiple fill coats I put on the board.  But in the end this will be a strong board that will last a long time.

I do like the momentum the additional weight produces.

Watching the board emerge during these last few steps in a build are pretty exciting.

Garage Works - 10/13/2024

Yesterday I got to spend a lot of time in the garage.

First up was sanding No.38

And sanding.  And more sanding.  I got the board through 40-80-120-180-220-320 grits.

Then I went ahead and got the vent and leash plugs installed.  I played with some different foot pad configurations - gotta let those settle out (too many variations).

Then I worked on these two - Kalani's new to him Drifter 72 and No.33

After Kalani brought this board home, he found a soft spot.  I filled it with milled fibers/epoxy, placed a small patch over the open ding, then placed this bigger cap patch.  Today I'll sand off the excess, place a fill coat and this one should be good.

This toe bar had come loose on No.33

I used rubber cement and it's as good as new.

It's amazing what happens when you get used to something and then it suddenly isn't there - I use the tactile feedback to know my front foot is at the sweet spot.

Today I'll sand down the plugs on No.38, give it a wash down to get the sanding dust off and spray a wear coat on it.  No.38 is going to be wicked good!!!!

Garage Works - 6/30/2024

I got a lot done in the garage today.

First up was sanding No.37.  Here's the top deck all sanded.

And here's the bottom deck all sanded and the tracks routed out

And the vent and leash plugs installed (plus a little epoxy to add material to some thin spots).

I just need to sand down the plugs, clean up the new epoxy spots then spray clear coat.  I'm trying to work out the deck pad layout.  That's another couple of days of work (about two hours a day because of drying and adhesive sticking time).

I also broke out No.19 to get a repair that was sitting under duct tape fixed properly.  There's been a few people hinting at wanting to learn - I figure I can sell off my old stuff (GoFoil and Takuma, and the bigger Reedins) if I can get them through the learning curve.  And Nick uses this board when he comes to Oahu.

It just really needed a little sanding and a patch of 4 ounce fiberglass.

Then I addressed the multiple harnesses I have in the garage.  The wing harness has seen better days and I have a T9 that has just been sitting there - so I transferred all the modifications over from the T8 to the T9.

I also put the new kiting hook on the Pyro that I had sitting around.

These have been with me for a long time - letting go of things like this is like saying goodbye to an old friend.  Thanks for covering my ass for all these sessions -

Garage Works - 5/19/2024

I've actually been doing work in the garage, but not documenting it.  I got the Spitfire 840 all patched up and I've been sanding No.36 a little bit a t a time.

Moving forward, I decided to start the repairs on the Cabrinha H800.  I used the glazing putty to fill the deeper scratches.  Here I am sanding them down. 

Then I used the solid paint pen to get the gaps as close to the surrounding areas.  It took a few iterations, but it's better than 95% now.  I also put a Donaldson trailing edge on the foil.

I didn't sand beyond 320 because I had errands to run - but I got through the hard part.

And talking about hard parts - I got through the rough sanding on No.36 today.

Here's the bottom deck - 

And the top deck.

After dinner, I drilled in the holes for the plugs and got them epoxied in.

I used the extra epoxy to put one more thin fill coat on the board and close up a few known issue spots (unruly innegra, some shallow fish eyes, and a couple of holes near a foot strap insert).

Tomorrow I'll sand this fill coat and the vent and leash plugs.  I'll also open up the mast tracks.  If I have it in me, I'll also try to get through the other sanding grits (80-120-180-220-320-400).  That shouldn't take too long - but there is also some surf out there still...

Garage Works - 4/14/2024

Yesterday had some stormy weather forecasted so I skipped the dawn patrol and focused fully on finishing Matt's light wind wing foiling board (No.35).

I did some light adjusting on the edges of the tracks, sprayed the entire board with a couple of layers of clear coat, and got the vent plug installed.

Here's the signature block for future reference - 6'6" x 20.5" x 3.75"

And just in time - Matt swung by to pick the board up.

I think he was more stoked than I was!

I told him to bring the board back once he figured out how he wanted the deck pad laid out.

On to the next one!!!

Garage Works - 1/23/2024

Yesterday I received the Evolution Cedrus Wind mast that I ordered back in November.

This thing looks SICK!!!

And yes - I am an early adopter!!!

Tomorrow there will be suitable conditions to get this mast wet and ridden hard!

Also yesterday, I finally figured out how to tie these ringed leashes.  I plan on using these to hook my wing leashes onto so they hook metal to metal.

And today, I drilled out the holes for the leash plug, the vent and two 1-hole foot strap inserts (to be used as a top deck handle).

Tomorrow the SW winds will be up - I am looking forward to winging with the Evolution Cedrus Wind mast!!!!

Garage Works - 9/8/2023

Today I started out on the bottom deck by filling some of the low spots with straight epoxy.

After that hardened - I addressed the top deck and the 2 plugs.  For future reference - 0.70 ounces works for both plugs (I wasted 1.4 ounces of epoxy...)

Tomorrow is sanding the touchup spots and the plugs.  Then I'll spray the clear coat on and figure out the deck pad layout.  That'll get me 24 hours for the adhesive to cure before anointing No.32 on Sunday when the winds pick back up!!!!