Garage Works - 10/21/2023 (Early)

And spent some time in the garage today trying to get the repairs done and out.

This is the latest set of dings that Tim put in the Greedy Beaver (collision with a SUP).

Not sure how this cluster happened...

Got the bad one filled.  I'll sand this tomorrow and place glass over it.

And I sanded the slot and the blocks for Prayot's foilboard mast track repair.  Fits like a glove!

And here it is epoxied into place.  This is a good, tight, clean installation.  I put a wrap of innegra around the block.  This is going to be bulletproof (but maybe not Prayot-proof).

And Marlon was sanding away.  Sand, sand, sand, and more sand....

Garage Works - 8/10/2023

And taking a break from foiling, I even got a lot of work done on garage projects - this is La's surfboard.  I'm smoothing out the old delam repair and a couple of small dings so it is water tight... she may actually go and use it soon....

Here it is sanded down -

A layer of 4 ounce glass and a coat of epoxy goes a long way to smoothing out the older repair.

These are the two forward rail dings - I should barely have to sand these - mainly blending them in with the rest of the board.

And I epoxied in the footstrap reinforcement blocks into No.32

This weekend I'll cut out the slots for the inserts, get those cleaned up and epoxied in place.  I want to also get the mast track boxes cutout and the boxes epoxied in on the bottom deck.  If I get there, I should also laminate the board.

I'll add the fill coat on La's board, and cut the finbox slot on Ken's board.

That's a lot of stuff to get done (in addition to renting a giant ladder to fix my gutters, pressure washing our teak lawn furniture, watering La's plants, yup.....).

Garage Works - 8/1/2023

Since I couldn't go foiling today, I figured I should go full bore on No.32 and get this thing finished.

I had originally planned on just marking the locations of the footstrap inserts -

But I went ahead and routed out the slots.

Not bad spacing.  It's not so tight that I can't put a layer of fiberglass under the blocks, but not loose that it'll take a bunch of epoxy to fill.

Those of you with discerning eyes will have noticed the two extra blocks out towards the nose.  These are for mounting the Foil Drive battery box.

I even had enough sunlight to rout out the SUP handle.

Pretty amazing how much work can get done when I'm not out foiling ;)

Garage Works - 5/18/2023

I worked on this board repair some more today.  I lined the box with two + layers of carbon fiber, got the divynicell set in and the laps laid flat.

Here's the board with the weights and clamps off.

And here is the board with the spaces between the blocks and the walls filled with epoxy/aerosil.

Tomorrow I'll sand and grind down the blocks to the right shape.  Then I'll set the boxes in epoxy and add the carbon fiber cap sheets.

That'll leave sanding and adding clear coat for Saturday.

Garage Works - 6/28/2022

I'm pretty much finished with all the repairs - the patches on two of the four spots I addressed yesterday came off when I removed the peel ply.  This afternoon I applied patches again, but used saranwrap instead of peel ply.

I also got Roland's surfboard all sanded down (but used solareez to fill a couple of other open dings - I have to sand those down and then the surfboard is done).  And I got his wing board all painted up as well.

And finally I worked on fine tuning the shape of the new wing board.  I feel much better about the shape now - had to spend a bunch of time sanding the starboard front quarter to get it close to symmetric with the port side.  I also got ambitious and outlined the foot strap insert slots - and even tried to rout one open - but with the sun going down, it was getting hard for me to see the alignment of the router bit.  I figured I should wait for sunlight.

I'll get the inserts epoxied in and a fill slurry to level out the area immediately around the inserts.  After that, I'll laminate the top deck - innegra nose to tail, and heel patches (to see if I can avoid the d-cell planks and the weight that brings, but without losing strength - I'll have deck pads on the board anyways).  I'll still have to install the handle on the bottom deck before I can laminate the bottom deck on - in a nutshell I still have a bunch of work to do on this board.  I'm thinking I have a couple more weekends to go.

Garage Works - 6/27/2022

And this was today.  I sanded the excess resin from Kalani's wing board and Roland's wing board and surfboard.  Then I added more fill coat to Roland's surfboard.

On the wing boards, I added some 2 ounce fiberglass to make sure there are no more leaks.  You can see the four spots I addressed weeping.  Some light sanding tomorrow, followed by clear coat and this should be done.

And here's Roland's tail repair.

Cover patch on this one too on top of the milled fiber fill.  After some light sanding , I'll spray paint this and call it done.

Once these are done, I can go wing (just in time - the wind is supposed to really turn on starting Wednesday).

Garage Works - 6/26/2022

This was yesterday - epoxied in the d-cell reinforcement blocks for the foot straps.  I placed innegra in the bottom of the slots since there really isn't a weight penalty.

Then I hooked up the vacuum to Roland's wing board to pull out whatever water was stuck inside.

I sanded down the repair work on Roland's surfboard.

I also added fill to Kalani's wing board to close off the spots that were weeping water.

There are alot of projects in this picture (two prone foil boards that need to be cut out of the blank, No.25, Roland's wing foiling board and surfboard, Kalani's wing board, Eddy's wing board...)

Garage Works - 6/11/2022

The family took off for activities early this morning - that left me with time to test out the new lawn mower and get some work done in the garage.   First up was cutting the d-cell strips I epoxied together. 

I cut four of the strips to lengths that will work for footstrap reinforcement block inserts.

That's a lot of footstraps...

Then I cut the last two strips to lengths that can work as cutouts for the ends of the mast track reinforcement blocks.  I'm not entirely sure these are needed - but I may try this as an add on the next prone foiling board I build.

And after all that, I worked on the fitment of the Kujira front foils onto the Stringy fuselage.  I've gotten the 980, 1095 and the 1440 to all fit well on the Stringy fuses - the 1210 is revolting against me on this (and that foil is the almost singular reason I got the Stringy fuses).

I also got the Stringy GoFoil (direct mount on the Project Cedrus mast) fuselage shimmed up - gonna need that today...

Garage Works - No.25

After surfing this morning, I worked on some garage projects.  I got the reinforcement block for the mast track sanded down to match the height of the surrounding blank.  Then I lined the hole with carbon and a layer of innegra.

I used about 5.6 ounces of epoxy to line the hole and saturate the laminates.  I used a roller to spread the epoxy evenly.  Then I spread some epoxy on the reinforcement block to make sure there would be a bond, and then stuck it in.

There was a little pull on the side pieces of carbon, but nothing catastrophic.  I used saran wrap to keep the laminates and the epoxy flat. 

I also finally epoxied the divynicell strips together (this needed to be done a long time ago).  I'll figure out what size these need to be assembled to in order to use them as footstrap reinforcement blocks and augment mast track reinforcement blocks (under the ends of the Futures boxes). 

Resetting Foil Straps and Board Repairs

This was Friday evening - I finished the repairs on Shari's board and moved on to working on Marvin's.  He asked that I change the front foot strap inserts over to a regular foot stance, and level the deck (from all the pressure dings).  First cut was to see what I would be dealing with - no high density foam.

Marvin did come over to go over the new foot strap locations - here is where we settled.

This will be a project - but should be fun.

Garage Works -11/11/2021

After foiling and breakfast, I headed to the garage to knock out some progress on the projects.  I sanded the HS1532CS trailing edge for a third time and placed a third coat of epoxy on.  After it cured I sanded it down yet again, and later this evening I'll get the last coat on, and get that through the whole sanding regime.

Then I sized up the latest ding repair job.  Went ahead and drew out what I thought needed to be cut out.

Taped off the deck so the wax job doesn't get gummed up.

Cut out the ding.

This looks like 100% fiberglass - no carbon...

And then I spliced on another piece of EPS.  I may get this dialed in this evening (cutting off the excess and sanding it down so the fiber can be laminated on).

Then I got the fiberglass cut out that will live at the bottom of the divynicell sheeting.

And I epoxied it in place.  The glass was 6 ounce fabric under the front decking and 4 ounce in the rear foot decking.  I mixed up 4.2 ounces of resin in order to make sure the cloth was saturated (the glass only weighed 1.5 ounces - so almost a 3 to 1 ratio.

The last thing I did in the garage before lunch was to sand Marvin's 15" rear stabilizer through the 40 grit sanding.  Lunch and errands are ongoing now - but I'll likely hit the garage again once I get back home.