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09-01-2009, 8:20 PM
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It's that time again! I have a few changes I want to try so I thought I'd do the entire build thread. I have enough foam for some projects. Depending how I cut the rockers I should get a minimum of 6 blanks from that.
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09-01-2009, 8:24 PM
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A close up of the two different boards. The BIG pellet board is 1 pound foam, the other is 2 pound foam.
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09-01-2009, 8:33 PM
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09-01-2009, 8:33 PM
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09-01-2009, 8:55 PM
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Rocker hotwired into the foam.
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09-01-2009, 8:57 PM
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I have a template that I use for various things and here I am using it to mark the curve where I will cut the foam to insert the stringers.
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09-01-2009, 9:00 PM
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I just use a jigsaw to cut the blank where the stringers will go. I sand both sides and that gives me the clearance to glue up the stringers.
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09-02-2009, 7:39 PM
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I use GG to glue up the stringers to the foam. The foaming helps fill any imperfections. I also leave the stringers a bit proud at this point as I'll be shaping the bottom pretty extensively. I tape the pieces together to hold it in place long enough to transfer the whole mess into the bag. I leave it there for a few hours until the GG cures.
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Join Date: Jan 2009
09-03-2009, 6:29 AM
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SD , i see you have alot of tail rocker on the core??
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09-03-2009, 8:50 AM
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Yeah, it's 1+ inch. The pictures are a bit deceiving because it's oversize. I'll end up trimming about 3" total from the length, most of that from the tail.
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Join Date: Jan 2009
09-03-2009, 9:12 AM
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are you going to try a tail channel??
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09-03-2009, 9:22 AM
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We tried that a year or so ago with Roush. I noticed that SS is using that on their 2010 board - I think they are calling it the Elevation. It COULD add some extra drive and COULD help stability with sketchy landings, but we also found that it wasn't consistent. SS uses a V out the tail so that may help the consistency issue. Concaves can be a myriad of different shapes, I screwed one up (wait, I mean I shaped one DIFFERENTLY ) and it wasn't a smooth semi-circle. I want to try shaping different caves on the bottom to seem how that affects speed and rail-to-rail responsiveness.
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Join Date: Jan 2009
09-03-2009, 10:18 AM
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yea i think a v out the back with a channel is the way to do it if that is what you want.
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Join Date: Jan 2009
09-03-2009, 1:20 PM
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I forgot that i saw grindwater with a board that had nose and tail channels at the expo 2 weeks ago.
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09-03-2009, 8:27 PM
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That's interesting that they have channels at the nose, might help stability some when the board is revert. I've "skinned" the blank to remove the proud stringers, excess GG and level the foam. Then I redraw the centerline and outline.
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09-04-2009, 7:14 PM
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Laminating the deck. First layer of 4 oz. I got some cheap E glass that is 50" wide. A 5 foot run will yield two 25" x 5' pieces, so I can get one top and bottom piece from that length
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09-04-2009, 7:16 PM
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Trim one 24" x 60" piece to size and cut some darts for the wings and round tail.
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09-04-2009, 7:17 PM
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Trim one 24" x 60" piece to size and cut some darts for the wings and round tail.
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09-04-2009, 7:23 PM
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I mixed about 8 oz of epoxy to make sure I didn't run out. Spread that across the top, wet the lap, flip to do the lap and then flip back.
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09-04-2009, 7:31 PM
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I've been working on it for about 7 hours, spread over 4 days. All of the above could basically be completed in a single day. The epoxy needs to cure, so I am at a stopping point. The lamination portion doesn't require much labor hours, but the epoxy cures slowly, so the elapsed time is significant. Excluding the time shopping for supplies, I think it's possible to finish a board in 10 hours, spread over 7 days.
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Join Date: Jan 2009
09-04-2009, 8:59 PM
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you are right about the time frame , i like your new stand, and are you just going with 4oz. on top deck or will you be adding some superfibers. no vac bag this time? I made a new stand as well its a box made from 2x10 wood 2' long with seadek on top and bottom, this box sits on a table that have been covered with plastic , i got sick of the SD style shoes and epoxy stuck to floor
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Join Date: Nov 2006
09-04-2009, 9:00 PM
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Hey Jeff, that new ventilation system seems pretty effective. I always like to see your shop photos.
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09-05-2009, 6:18 AM
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@ jim beam - no just 4/4 x 4 on this one. I'm testing the different bottom shape and it has a 90% chance of being crap but...I have to test it. I'd love to see a picture of your new stands, can you post one up, please? @ art - you like that system? I have the entire OUT-OF-DOORS! Although I just checked my lamination and I have 8,123,661 bugs stuck in the cured epoxy this morning. Sheesh.
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Join Date: Jan 2009
09-05-2009, 6:34 AM
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a board sits on top of a box with seadek on top and bottom for traction, then it rests on my table . i think i will make a drain pain from plywood & 2x4 that lays on the table so i can put zipzorb in to catch the epoxy when it drips instead of it dripping onto plastic. or better yet ask my dad to break some aluminum into a pan.
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09-05-2009, 8:46 PM
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Innovative jimbeam, Bottom lamination done this evening
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Join Date: Jan 2009
09-06-2009, 7:59 AM
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need a little fast& final on those bumps
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09-06-2009, 12:10 PM
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I was inspired by the wicked resin swirls that Rock is doing for the MoB group's boards. JL posted them at the end of this thread: http://www.wakeworld.com/MB/Discus/messages/87668/721849.html?1252253836 Taking inventory, I only had red and black! Anyway, it was fun! Like fingerpainting in kindergarten.
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09-06-2009, 2:09 PM
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09-06-2009, 4:36 PM
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Thanks JL - Rock's graphics are sweet. Will Wakesurf Magazine show some of the omposite work that he's doing? My finished graphics. Deck Bottom
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09-06-2009, 8:21 PM
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LOL! Medieval - like with Stretch and the ancient greek "ghetto"; Medieval, in this context, is ALSO anciet greek, that translates to: "wow! that looks like it was done by a TRUE master."
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09-06-2009, 8:22 PM
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I'm lookimng forward to some details on Rock's composite work. I'll look for it in the next issue of WM.
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Join Date: Jun 2005
09-06-2009, 8:50 PM
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Surfdad, it looks like your board is a sacrificial altar
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09-06-2009, 8:55 PM
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LOL I don't even want to KNOW how you know that, but let me just clarify - do you mean that in the sacrifical altar is the "coolest board ever", sort of way?
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Join Date: Jun 2005
09-06-2009, 10:42 PM
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Jeff, "coolest board eve"r sort of way. its the new lingo.
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09-07-2009, 5:31 AM
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YES! I can't wait to use that in a sentence and be a hipster! "Hey sweetie, that new outfit looks sooo good! It's sacrifical altar hot on you!" I'll owe my lovely wife's reaction to you, Mitch!
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Join Date: Jan 2009
09-07-2009, 5:43 AM
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SD , chek out these wings , lol. everyone have a good holiday
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09-07-2009, 5:53 AM
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I love the graphic! What board is that a picture of?
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Join Date: Jan 2009
09-07-2009, 6:01 AM
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uhhh , you can find it on another site , it looks to be a wide diamond tail with wings
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Join Date: Aug 2005
09-07-2009, 12:16 PM
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looks like board from hell
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Join Date: Jan 2009
09-07-2009, 12:22 PM
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@SD did you tape up your fin boxes or install them after. @Petr how is your build going , no word in a long time??
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09-07-2009, 12:30 PM
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I installed the boxes afterwards. Petr, "from hell" in a super cool best ever board kind of way, right? I'll NEVER learn all these new terms!!!
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Join Date: Aug 2005
09-07-2009, 2:11 PM
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JIM - thanx for asking, thats funny, just RIGHT NOW I finished my first paint job. Shot pictures of it and I'm just in the middle of downloading them in PC and i will post them in my new thread.... So wait a little... JEFF - dont worry, everything you do is SUPER COOL!!!
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09-07-2009, 3:41 PM
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Super cool is my middle name! I'm done with this build, I believe my total time invested including the secondary yellow swirl hit 10 hours.
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09-07-2009, 3:47 PM
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Epoxy is funny stuff. It will get soft at the temperature it cures at, so if the board is built in 80 degree temperatures, 7 months from now if that same board is subjected to 90 degree temperatures the epoxy will soften - the typical result is a delam. Post curing is the process of heating the board up to a temperature HIGHER than the normal intended temperature, but less than 150 which is where EPS liquifies. This is my super duper specialized post cure oven. 2 mil garbage bag left in the sun.
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Join Date: Aug 2005
09-07-2009, 5:08 PM
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Oh that super simple smart!! And cool too
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Join Date: Aug 2005
09-07-2009, 5:13 PM
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So when I lefted my board in dark sock on the sun it was just postcuring
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Join Date: Jan 2009
09-07-2009, 6:25 PM
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i will keep mine in the jeep all day tuesday , then sand hotcoat.
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09-07-2009, 8:53 PM
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Yeah...that black bag absorps the heat and it will add 40 degrees to the ambient air temp. It's almost mechanically accurate. @ Petr - YES, postcuring not ruining it! @ jim beam - I've heard of folks doing that in any of the sunbelt areas. What I like with the garbage bag post cure oven is the consistent increase in temperature. I don't know why it's consistent, but in our weather I consistently get a 40 degree increase in the interior from the ambient air temperature.
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Join Date: Apr 2006
09-08-2009, 6:45 AM
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I'll cook mine during construction for even better results
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Join Date: Oct 2007
09-08-2009, 2:57 PM
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ha!
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09-08-2009, 3:44 PM
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I've done heat/post cure on an EPS board during a hot coat during summer and melted it Not better in my book, although watching it smoke was pretty cool. One of the benefits of high density foam is that it can withstand the heat. In a hand lam like this board, heating it as one side is laminated would tend to cause distortion. Caskimmer has rocker tables and cool tools! I'd guess technically epoxy has three stages of curing - initial which is just to the point of gelling, the B stage where it can be handled, and removed from clamping pressure, but isn't fully cured and then the final cure which can take weeks. In a true technical sense, post cure can be heating anytime after the initial cure. My understanding is that room temperature cure epoxies have a mix of elevated and room temperature components and so heating the cured epoxy activates those high temperature components so they crosslink. Post curing reduces the final curing phase from several weeks to maybe a day and also soldifies the heat deflection which is a huge problem for us out on the boat in July.
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