Garage Works - 3/26/2023

After a nap, I went out into the garage to work on the boards in progress.  First up was getting the volume distribution on the big prone/light wind winging board dialled in.

I broke out the Makita 18V planer for this work.

I'm comfortable with where the top deck and bottom rocker are at currently.  I'll try and keep as much volume on this as possible, so that'll mean minimal foam removal.  There will be chines on the bottom deck, but most of the removal will be at the tail block - which I haven't completely figured out yet.

I'll go through some iterations in my head - but I think it will involve tapering after the track boxes and keeping the bottom as flat as I can.

This will most likely become a 'V' tail.

And while I was at it, I got the template marked out on the new prone foil board (I need to have more room forward of where the current 4'8" track is installed).

I didn't hook up the vacuum to planer today - just focused on removing bulk foam.

And with these short prone boards, since I know how I want them to end up, the rough shaping goes pretty quick.  I got this one pretty much completed today (still need to sand it and then I'll install the mast track reinforcement block, etc, etc, etc).

The boxes are laid out 2" further forward than the current board.

When you know what you want to emerge from the blank, shaping is easy - just takes time (so you don't take too much too fast).

I also really like shaping stringerless blanks - so easy when you don't have to shave down stringers.

I really like this length - the current board has been super versatile.  And the shorter boards I've made since have helped me define what works for me and the waves I usually find myself in.  

Wing Foiling Board Progress - Monday

I wanted to get some more work done on the wing foiling board - but I needed to get some errands done as well.  I mowed the lawn, pulled a bunch of weeds, helped La with the hedge trimming, and chipped off some of the old paint on the roof rack door latches (same as the rear set I did last month).  In between all that I did route out the slot for the handle I'm placing on the bottom of the wing foiling board, and set it in with epoxy (mixed with milled fibers).

It set nicely but as I was checking on it, it was exotherming pretty healthily.  I kept checking on it - and it didn't burn through - but the handle was pretty hot.

And after thinking about the glassing schedule and the footstrap inserts, I'm settling on no footstraps on this one and different layers on each side.  The bottom deck will get a carbon layer, topped with a layer of innegra, a carbon patch over the fin boxes, and all capped with fiberglass.  The innegra is supposed to be white, so I should cover up the carbon layer.  The top deck will get 2 layers of innegra and a cap sheet of fiberglass.  With the stringer in place, I shouldn't lose any energy as the bottom carbon will stiffen up the board.  I'm hopeful the innegra is as bulletproof as I've been reading - and that it isn't too hard to work with.

Sunday Progress

I took a planer to the bottom deck to level out the high points (like the patched area where I knocked out a piece with the straight router bit, and another where the excess resin bubbled out from under the block).  Pretty harmless.  After that I marked the lines where the boxes needed to go and proceeded to cut.

I took my time getting things set up - having had messed up almost ever board before (nevermind I was able to salvage them all - I'm trying to get to the point where I make flawless cuts) I wanted to do this one correctly.  I shimmed the low end and made sure both ends were equally spaced.  Then I placed the box on top of the template and measured that distance.  With the top to bottom distance, I set up the router to make that deep of a cut.  After both cuts, I did notice one thing - I had flipped the shims and the slight height difference actually showed in the boxes when I had them set in place - so I still had to make a salvage (if ever so slight - I'll take this as a win!!!!).

I set the boxes and got them taped off.  I am still pondering/researching the glassing schedule... I've got to figure out what to put where - carbon sheets/tape, fiberglass (on top - th.is one is easiest), and 2oz innegra.  The innegra is the new layer to consider.  Looking online, the innegra seems to be a bulletproof layer - but you can't sand it.  I'll get it figured out tomorrow (so I can keep this going) - bottom deck, then when that is cured flip and route out slots for dcell inserts (I keep thinking I should place imbedded footstrap inserts in - more control at some point and for jumping).  Or I could just use stick ons...

Block Slots Routed Out

I routed out the slots for the reinforcement blocks.  I didn't have access to one of my kids (Noe went sailing and Marlon drove La and Noe) so I did not use a vacuum to grab the offcuts.  There was foam particles everywhere - I looked like a snowman.

These slot were pretty good - a couple of oversized spots, but I think they can help get rid of any excess epoxy.  After I cut the slots, I went surfing with Marlon, so I'll epoxy these in place tomorrow.  That should set me up for cutting out the slots for the finboxes, epoxying those in, fine sanding the rest of the board, and putting on a seal coat. That will leave glassing for early next week and sanding later in the week.  A little bit everyday and this will get done.

Wing Board Progress

I've been putting a little time each day since Saturday working on the rough shaping of this latest board.  I already posted Saturday's planer work, so for this post I'll start with Sunday's work with the coarse surform and dragon skin.

I got it to probably 85% - but in looking at the pictures, the tail has too much kick in it and there are some high spots in various points.

Here is today's results - I got the tail worked down, the high spots lowered - that's it for the rough shaping.

I'm still debating the use of dcell under foot - I think I'll go easy on myself and just double up on the innegra (patches).  I'll mark up the slots for the higher density foam blocks for the finboxes (mast track) and put a first mark up for the foot strap inserts (I'll have to do some measuring/proportioning to settle in - which is fine - I'll have the time since the foil block has to go in first).  That plus the fine sanding and seal coat will likely take me to the weekend.  Last picture - this was my inspiration for this board - seriously.

Rough Shaping the 5'2" Wing Foiling Board

Marlon as an infection on his leg, so I decided to pass on surfing yesterday.  Not to mention the surf is way down (first time in a while actually).  Instead, I decided to break out the planer and get the WFB further down the path to getting wet.

Most to the trimming was on the bottom of the board - bottom of the rails and the tail.  I had to trim up the nose a bit also - but it was all done in about 45 minutes.  I also worked on the top - rails, nose, tail - then did a pass over the flats top and bottom to get rid of the rough foam (makes sanding way easier even if I am not taking much off - starting everything at the same consistency is always best).

Today the surf is even worse - so I'll get the rails blended in (dragon skin - drywall mud rough sander), and I'll try to get the sanding done.  From there I'll need to cut out holes for the foot strap inserts, the leash plug and the mast tracks.  I was thinking of using dcell under the feet again - but I am also planning on using innegra for the laminate.  I think if I can double up where my heels will go, I can forego the dcell patches (which means less work).

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.

Did Lots of Work in the Garage

Started out routing out the voids on the new 4'10" prone foil board.

Then moved on to skinning the duo finned stubby blank.

Afterwards I helped Marlon grind open the fin boxes on his board and continued on with sanding both the top and bottom decks with 40 and 80 grit.

I went ahead and removed the old manual vent on the 5'2" prone foil board and set in a new automatic vent in the same place.

Marlon and I drilled out a spot for the leash plug and got that set.  Tomorrow we'll fill in some air bubbles we found on the fin boxes.  If we do this in the morning, we should be able to grind down the leash plug and the boxes, then move on to the final sanding.

And I went ahead and planned out the fixing of the ding I acquired on the pigfish (the board slipped from my hands when I was getting out of the water - I thought I caught it, but apparently I didn't).  And this is where my OCD kicks in.

I also mowed the lawn, cooked breakfast and lunch (and dinner for me - everyone else ate already) -  I think I'm dealing with my mom's passing by working on things (and I'm talking about it on this blog).