Garage Works - 8/27/2025

I sanded the last epoxy/carbon add to bulk up the rake on the tip.

Better now than when I got it!!!

The tip is more solid (that is one of the criticisms I have of AFS front foils - the wing tips are fragile...)

It's already been out on the water!!!

Garage Works - 8/9/2025

These projects were completed yesterday.

This first one is Prayot's PPC M1 wing repair.  The strut bladder gave way.  These higher pressure, exotic material wings need to have thicker bladders - any high stitch or small piece of debris can be a seed for a bladder blow out.

I patch three spots and also armored them with extra layers of Tear Aid.

This is Marlon's Dominator Pro all patched up.  He took it out to Hau Bush this morning and got some good rides.

And this is Mark's wing board now converted to support Foil Drive.  I put windows on the top deck -

And the bottom deck.

And fixed a few dings that looked like they were water infiltration points.

All done!

Next up are Duke's paddle and Marlon's prone foil board.

Garage Works - 8/8/2025

And this evening I sanded the fill on the ding on Marlon's new board.  Then I colored in the rails.  And finally I placed the 2 ounce cap sheet.

He can use this tomorrow during the big swell - then after I'll sand it and fair every thing in.  But come morning - everything should be water tight and rideable.

And I also sanded the fill on the ding on Mark's board.  And while I had epoxy mixed and available, I placed a small patch over the sanded ding.

I'll do a light sanding on the windows and the ding repair tomorrow, spray some clear coat and this should be good to go.

Garage Works - 8/6/2025

There are a couple of boards in the garage for repairs.

This is Marlon's brand new Firewire Dominator Pro.  First time out and he duck dives right into a shallow spot at Kewalo's

Easy fix - but it'll take a couple of days.  Here I've already sanded the break down and filled it with milled fibers.

I'll sand, color the rail, and place a fiberglass patch over this area (there are some light superficial scratches at the nose).

And this is Mark's board that Maile is using for a Foil Drive board.

I got asked to put signal windows in place.

And there was a rail ding (that I feel compelled to fix). 

Here is the bottom deck window.

And the top deck window.

I should be done with both of these by Friday.

Garage Works - 7/1/2025

I went ahead and repaired the crack in No.41 yesterday evening.

You can just see the crack here -

Not sure why I added this picture - kinda the same thing as the first.

And this is the peel ply over the 2 ounce patch placed on with epoxy.

I already pulled the peel ply this morning, sanded the repair and sprayed replacement clear coat.  I'll post more pictures of the completed repair shortly (since the wind is in that "in between" level - I figured I should rest up today after yesterday - that way when the wind comes up tomorrow, I'm better prepared - I'm not doing anything else... might as well oogle over the board and stick some more stickers on). 

Garage Works - 6/28/2025

And also from yesterday - I spent some time in the garage trying to get No.41 over the finish line.

After remembering I had a trench in this board, I looked to see if the area I cut to place the back foot strap was clear of the trench - NOPE.

That made my decision to fill and patch easy - so no foot strap inserts on No.41 

After thinking about the repair, I figured it was easiest just to fill with milled fibers/epoxy, then add carbon patches above the cut areas.

And here it is all patched and waiting for the epoxy to harden. 

I had already pulled the peel ply and added the fill coat last night, and this morning I sanded and sprayed clear coat - but that's for another post.

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 - 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!

Garage Works - 6/22/2025

I got this sewing machine for Father's Day, but today was the first time I plugged it in.  I also organized the feet and other accessories.  I'll have to practice on it a bit later - need to finish No.41 (as Miles is asking for a board to be made).

Speaking of No.41 - yesterday I sanded the top and bottom - and for the most part there weren't any real surprises.  It wasn't perfect - there were still some low spots, so that meant another fill coat.

I taped up the board for a bottom deck coat first.

You can see some of the low spots.

I used Pro-Link for the bottom fill - that won't be hidden by deck pads so it's worth putting it on the bottom.

And this evening I found some time to get the top deck coated.  I used regular aluzine epoxy for this coat.

Tomorrow I'll sand both sides through the sanding regime, then place another fill coat on the side of the trench I hadn't gotten to yet.  After that hardens, I'll get the leash plug and vent installed.

This one is getting close to anointment!

Garage Works - 6/20/2025

I got a lot of work done on No.41 today.  I sanded the top deck, cleaned up the signal windows, placed a fiberglass patch over the windows, and got a fill coat on the whole deck.

Then I sanded the bottom deck, got some label decals on, and got a fill coat on it as well.

Tomorrow I'll sand the edges, try to identify the remaining low spots, then add another fill coat (or two). 

If the fill is looking good, I'll try to get the vent and leash plugs in also

Garage Works - 6/19/2025

And I got some time in the garage today.

I drilled in two signal windows on the top deck of No.41.  I also sanded these down later (but don't have a picture of that).

Then I sanded down the nose repair on Rick's board.  I went ahead and placed a pigmented fill coat on and sanded that down as well.

All done.

I need to get a fill coat on the top deck of No.41

Lots of fill-sand-fill-sand in the near future.

Garage Works - 6/18/2025

I haven't found a good way to dry the parawings yet.

Still looking...

And I got the nose patches on Rick's board repair.

I should be able to apply a pigmented fill coat tomorrow, and this board can go back to Rick on Friday.

I didn't take a picture, but I also placed a partial fill coat on the bottom deck towards the nose on No.41.  Tomorrow I'll be able to sand a little and apply the lables/decals.

Garage Works - 6/17/2025

And after the foiling session, cooking dinner and cleaning up a bit, I got a bit of time in the garage.

First up was an emergency ding repair for Rick.  This board fell out of its spot in his board rack.

Here's the nose ding all sanded and opened - ready for fill.

And I sanded the entire surface of No.41.

Here's the bottom.

Here's the top.

Here's the rear.

I found two spots that needed fill and a patch - so I took care of those this evening.  Fill on the right corner... and I didn't take a picture, but there is a patch towards the nose on the top deck.

And here is the nose job fill on Rick's board.

More sanding and filling in the immediate future for me.

Garage Works - 6/15/2025

Also on this 2025 Father's Day, I got lots of work done on No.41

After the epoxy fiasco yesterday, I got everything sanded and fixed this morning.  I'm glad the fiasco happened, but this board will be stronger now.

And this evening I was able to get the top deck lamination epoxied on.

The hard part is done!

A little lap sanding tomorrow, label stickers get placed, and a fill coat will go on.

The next day the other deck will get it's fill coat.  Sanding on Tuesday.  Secondary fill coats if necessary.

Plug installation (maybe Tuesday night) and Signal Window up on the nose.

Final fill coat on Wednesday.  This board will definitely be anointed by this coming weekend. 

Garage Works - 6/14/2025

I installed this parawing harness hook onto the NSI parawing pouch belt.  It works well!  I'll try it out on the water next time I go parawinging.

And I got a lot of work done on No.41

This is the carbon strips I'll apply to the bottom for stiffening.

And here they are installed.

I sanded that laminate smooth and then prepared to place the bottom on.

The first batch of epoxy cooked off a little quick - and I may have ruined a few areas of the bottom laminate.  I'll check tomorrow - if I need to I'll sand of the bad spots, and relaminate.

If I knock this out in the morning, I should be able to laminate the top deck tomorrow as well.  With all the extra work going into this build, it better perform well...