Garage Works - 3/9/2023

I saw this little planer at Lowes recently and thought it would be perfect for doing small area work on repairs and builds.

I can attest that this is a useful tool.

It is ultra light and fits in much smaller spaces than the other planers I have.  It is strong and cuts through hardened epoxy without any drama.

This surface is now flat as I need it without having spent more than 5 minutes working on the high areas (and it only took that long because I was learning which buttons did what).  On the repair project side of this, I'll use the sander to still knock down some even smaller irregularities, but then I'll go ahead and rout the slots for the finboxes.

The allternative to this would have been a sander using 40 grit - but that often leaves a bias in one direction or another (because of the spinning and what direction I go at the project area).  This planer works perfectly for this application.

I can also see this working rocker on the shorter boards I make - not having to deal with tool weight will let me focus on material removal and dialing in rocker.

This being a new tool system from Bosch, I can see getting the 12 volt barrel jig saw and 5" Random Orbital Palm Sander also.  I already have my heavy tools for longer span work - I've been waiting for this line of tools to come out (without even knowing it was in development).

NWFB Done!!!

Got the final-final sanding and the satin spray fill coat on this afternoon after work.

It did come out a little heavier than I thought it would - and funny thing is it kinda nose heavy - which is the exact opposite of what I was going for.  So experimentation wise, the extra carbon did contribute to more weight.  That is ok - bullet proof boards equal much less headache in the future.

I got the deck pads, the leash line, the vents and some stickers on this evening - I'll post pictures of the finished board tomorrow.  #20 all pau!!!

Bottom Inserts on the NWFB

After I mowed the lawn and helped La learn some carpentry, I felt compelled to get some more progress done on the Narrow Wing Foiling Board.

Measure - measure - measure - cut.

Actually came out perfect!

And I went ahead and cut out the bottom deck handle.

If the predicted south swell does not show up tomorrow, I can get these inserts epoxied in and laminate the bottom deck fabrics.

After that, I'll have to turn the board over, figure out where I'll place the footstrap inserts and route out the holes for the divynicell blocks.  Lots of work still to follow - but this is always the most critical step (so it's all downhill from here).

Getting Started on the Next Boards

I went to Fiberglass Hawaii yesterday to peruse the blank selection.  I was headed towards purchasing a 10'4" SUP B, but I saw they had foil board blanks now.  I ended up getting a 6'2" for a wing foil board (because it had the width I was looking for), and a 5'2" for a prone foil board.

Today, I cut out the templates that I had transferred from the paper versions I made this past weekend.  It turns out I had one that was uncut - Kalani's 4'8" Freedom Foil Boards Techno, so I had three templates to cut out and fair in.  I used the jigsaw to remove the bulk excess, then the garnet block to dial it in.

Tomorrow (or sometime soon) I'll transfer the template to the blank and cut the excess off.  I've also got to cut and grind out Tim's (another WPB foiler) HS1550 to repeat the chop shop job I did on Kalani's wing.  

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).  

Template Transfer and Cutting Out the Board

Inside every blank is a board waiting to emerge.  Here's this board starting the journey.  This stubby with Duo fin setup (plus a center box for single fin outings) should be really fun.

I took stock of how much blank there was in relation to the template.  I went ahead and extended the template on the board by about 3" (since there was room - I need all the help I can get).

This 5'10" fish blank is thick - the jigsaw with a normal blade was not long enough to get through it.  Might as well get started on this - I don't think the COVID-19 restrictions are going to get lifted anytime soon.

Marlon Grinding

Marlon grinding down the laps from the bottom lamination.

He did a pretty good job.  Building boards has actually been a good way to ride out the COVID-19 lockdown.

Next Step - Finboxes

Probably the most critical of tasks in building a surfboard is determining the fin placement.

I'm still researching this, but I'm hoping to converge later this week on a decision so I can get the boxes cut out and at least the bottom laminated before next week.

More Shaping - 3/28/2020

Today, in addition to mowing the lawn, I also spent time in the garage getting the shaping done on the two boards I am working on.  First up was the 4'10" foilboard.  I got through the dragon skin blending and the 50-100-180 grit sandpaper runs.  I think it came out really nice (but for some reason I didn't get a picture - I'll update this post when Marlon sends them).


Next, I worked on the asymmetric fish.  I got through the 100-180 sandpaper runs.

Will need to spec out the fin locations (this includes the foilboard) before glassing these boards.

Dialing in the Prone Foilboard

With the COVID-19 virus making its rounds, I have retreated to the garage and am punching out some boards to enjoy this summer.  Yesterday evening I spent some time cleaning up the rough shaping on the new prone foilboard.  Right now the dimensions on this one are 4'10"x20"x4.25" - will probably shrink just a bit as the blending occurs.

I wanted this to be a narrower version of the 4'10" I made last year (and one that is EPS).  I'll compensate the lost volume from the narrower width in more thickness in the back end.  I'll also play with some d-cell layering and targeted carbon placement (instead of all over).  If the wind is up again tomorrow afternoon, I likely start the fine shaping on this board (and the wind is light, I'll try to get some surf in).

100 Sanded Asymmetric Fish

I got the asymmetric fish sanded down to 100 grit.  The dimensions right now are 2 15/16" thick and 21 1/2" wide (I think the length is just under 5'11").  Probably mid 30's in volume.

Going to sand to 180, plot out the fin positions and get this ready for glassing.  For the record, I hate glassing.  And I really hate sanding.

Tuning in the Rails

We worked on the boards again this afternoon.  I helped Marlon get his rail bands cut, and then got him through the dragon skin work.  I forgot to take a picture, but it looked like he was getting confident using the planer.  We dialed in the rails and got some of the deck faired in also.

I did the same in the asymmetric fish.  I got the toe side rail adjusted so it is straighter (and more aesthetically pleasing to the eye); and the heel side tweaked.  I'm trying to preserve as much volume as possible - it is rather small... This is going to be one sick ride!!!  Tomorrow I want to get some more work done on the foilboard, but then we will be fairing in the decks and sanding screens - this should get us to fin placement and glassing.  At this rate, we'll be sanding the boards this weekend.

Electric Planer Day

Got some more work done on the boards today.  Marlon skinned his blank and got some additional trimming completed (the tucked under edge).  Still needs to get the rail bands cut - then we can move on to fairing in the rails with dragon skin (drywall sanding screen).

The electric planer can be intimidating if you haven't used it before - but after some coaching Marlon got the nuances down.

I got the asymmetric fish foiled out more, cut out the rail bands, dialed in the tail a bit, and got the tucked under edge cut in.  I used the surform to get the deck leveled out and the high points on the rails knocked down.  Tomorrow I'll also dial in the rails with dragon skin.

In this time of needing to play it safe for the benefit of us all - making a few new boards for this upcoming summer will help us keep to social distancing standards.

Pictures with Better Lighting

I'm trying to finish up some repair projects (not mine).  Since I was in the garage anyways...

Here is the asymmetric fish (I have to come up with a better name for this...).  I think this is way more aesthetically pleasing in comparison to the template before the additional trimming.

And here is the 4'10" foilboard.  I may play around with the tail a little bit more before I start planning for bottom rocker (flat-flat-flat).

And last but not least - Marlon faired in his template today.  He even used the surfboard ruler to get the symmetry closer.

Next will be skinning the blanks with the electric planer...

Goals and Ideas for the Next Boards

Marlon asked to shape his own board - so here we go.

He is looking at a 6'0" standard shortboard.

I am going to try my hand at a thick, short asymmetric.  Still deciding on the transitions.  Stay tuned...

Furthering the Cause

I spent a little time this afternoon working on the 4'6" prone foilboard.  Focus was on the bottom deck and rails today.

I used the planer to trim off a bunch of bulk - definitely going with the beveled bottom rail from now on.  After I got the blank to roughly where I needed it, I transitioned to dragon skin (drywall leveler) to start blending in the rails.

I'm going to try and make this one narrower than the 4'10" - shooting for 22".  Also going to try to keep the thickness - 3.5" so the volume and paddling power are high.

I ran out of daylight and had to call it quits for the day.  If I get home early enough tomorrow, I'll knock out the top deck and start the sanding regime.

More Sanding -

It never ends... at least it seems that way.  I got through the 60 grit final sanding (final before painting - and then there is more sanding after that).  I'll do a 120 and a 180 sand tomorrow.  After that I'll use a light colored spray paint to add protection against the direct sunlight.  Then I'll sand that coat down to just what is needed for said protection (see - the sanding never ends).  After that, I'll use a clear coat and cover everything to get it nice and shiny again.  After that - you guessed it - one last sanding - this one will be the 400 grit wet sand.

Then I'll drill out the leash plug hole and get that set.   If I get all this done tomorrow, I'll surf this on Monday (Veteran's Day!!!).

Sounds easy enough (not) - but I still haven't picked the paint color or printed out the logos.  I might just spray paint the logos on and use posca pens for the dimensions...

Getting Ready to Cut Out the Finbox Slots (for the Mast Track)

I sanded down some of the hardened epoxy high points (so laying the carbon fiber and fiberglass will be easier).

Then I measured out where the boxes will go - 90mm spread.

I'll make the cut tomorrow morning when there is natural sunlight (measure twice in good light - cut once).