Author Topic: Cowboy Foil Experiment Thread  (Read 26805 times)

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #225 on: June 13, 2018, 08:13:06 PM »
Please do, there's only a few of us doing this craziness. I hope someone can do me one better nd we can move forward a bit.

Charlie SUPUK got the wing down after I started this. I want to try his method next. I'm stoked on my fuse and mast, I'd like to have them separate but I've not sorted out how to really make that tight just yet.

Also my wing mount has too much play. I'm trying a fix in the next day or so.

Got the tail mount inserts in tonight, I'll be able to screw that wing on tomorrow. Getting so close.

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #226 on: June 22, 2018, 10:24:10 PM »
Final hotcoat going on now. Side 1 done.

Bought hardware from American Kiteboarding and that'll be here. Also have an O'Neil wakeboard vest coming from eBay.

Probably have to paddle this thing next weekend and then hope to get down to SD for some boat time soon as well. Pics to come.

jrandy

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Re: Cowboy Foil Experiment Thread
« Reply #227 on: June 24, 2018, 04:10:24 AM »
Go Cowboy go! Looking forward to seeing the finished pics.
http://pushheretosavealife.com/
Be safe, have fun. -J

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #228 on: June 24, 2018, 10:13:57 PM »
Ok, here are some shots of the hot coated parts. I posted both beauty shots and some showing some of the rough parts. I've decided not to sand it again and just see if it flies.

If one side of the mast is pretty smooth, the other is a bit rough. If it works well, I'll probably take that side down and redo it. But I'm ready to go.

My only concern is the middle screw hole that was put in to stop the "slop." I filled it pretty well with epoxy and hopefully coated the inside well. We will see. I'm hoping to do the wing mount one better on my next try. I used brass inserts and I'm pretty sure I'll be installing stainless steel ones before long.

Otherwise I'm happy with it and excited to see how it flies. Already found a friend to print a plug for my next wing. So I'm hopping back into Fusion360 as well.

Ride report next weekend I hope.

opie

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Re: Cowboy Foil Experiment Thread
« Reply #229 on: June 25, 2018, 04:32:55 AM »
So clean.  Nice work!  :)

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #230 on: June 25, 2018, 08:20:53 PM »
Thx man. I'm already planning the next in my mind. A word to all home builders starting out. The second one of everything is better. Don't stop at just one as your next one will be 100 times better.

SUPeter

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Re: Cowboy Foil Experiment Thread
« Reply #231 on: June 27, 2018, 05:38:35 AM »
Really cool!  Send us some vids when its flying.  Definitely looking stout enough to handle just about anything.  Have fun!

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #232 on: June 27, 2018, 07:44:18 PM »
I've got boat time set for Saturday. Can't wait!

clay

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Re: Cowboy Foil Experiment Thread
« Reply #233 on: June 27, 2018, 10:21:18 PM »
Cowboy, I am looking forward to the ride report!
Aloha, I welcome and appreciate all responses of positivity and good feeling.

YouTube: https://www.youtube.com/channel/UCOIE6FWr1SpWvbPJIIiEgog

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #234 on: June 28, 2018, 07:06:07 PM »
Ok guys I need some info from foil owners. I did mention that I've never seen a foil in person, right? Ahaahahaaaaa.  Yeah, this project is born of insanity.

I bolted up my rig tonight and it looks pretty good. For having never seen one of these and not having plans other than a bunch of dudes guiding me via the internet it's the foil equivalent of the Apollo missions to me.

However, how stiff is this thing supposed to be when it's on the wing on land? My mast is rock solid but the wing connection has a bit of flex so when I'm holding it sitting on the foil on land I can rock the board an inch or two side to side. Beyond that it picks up the corner of the wing. Is this "good enough" or should I be worried?

I'm assuming its impossible to make one 100% stiff and I hear of aluminum masts bending so I'm assuming all foils have some flex when a board is tweaking on them, no?

If not, let me know lol I'm assuming I'll know if it's too much Saturday. 😂😂

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #235 on: June 30, 2018, 05:32:44 PM »
Argh! Got behind the boat and after 2 min my wing snapped off almost exactly where I was worried it would. In good news it looks to have been lifting and flew smoothly under the water with no had drag. So I'm back to the garage but I feel like my design is on track.

I'll post pics later and a full explanation of the failure. It was so fun to do and I am anxious to get back in the horse. Hoping to turn the fix around fast. Need to get off my but and into the shop.

But overall, despite the break, it was a success and I'm fairly sure this thing will fly. So I'm energized to try again.

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #236 on: July 01, 2018, 10:21:36 AM »
Ok, starting my post mortem and remediation plans.

The above post about flex was from where the break happened. When I put that carbon tube on I had to put it over the plywood extension where the wing mounts. Instead of seriously limiting the amount of wood and running the carbon through it, I left off the thickest part of the carbon and ran it over the outside section that mated to the wing (where the 45 cut is. That left a weak spot at this critical juncture. I don't think I can use the paddle tube mount and am going to something more like the simpler flat fuselage over the wing or like the axis with a plate. Additionally I think I'll blend the top of this piece up to the front of the mast to make a brace as this wing will be holding 128lbs (in my case.)

Now that I understand where the load is and more what that load is, I can test on dry land. So that feels much better than guessing.

Now, the big question. Can I stand back the carbon and splice in a front piece without rebuilding the whole mast/fuse assembly? I think that if I cut the fuse and re-lay a full 9layers of carbon again I can get this strong enough.

Oh and a "you were right" to all the guys who told me that the strength was in the carbon. The plywood might as well have been cardboard when the force of the water hit it. The carbon is all that matters. Those of you thinking of doing this out of foam, go for it as I really think that if you went with a bit more carbon than I did you'd be fine.

I'll try to get pics up later and draw out what I'm thinking for the fix for you guys to review. I'm actually really excited again to build on this thing. Being in the water got my juices flowing again.

opie

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Re: Cowboy Foil Experiment Thread
« Reply #237 on: July 03, 2018, 03:55:19 PM »
Bummer, but I guess its just part of the process.  It's cool that you felt enough lift to give you faith in your design. 

Hopefully you can splice it back together and give some video of your first rides soon. :)

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #238 on: July 03, 2018, 09:20:03 PM »
Making it all worse, I got a cold and have been in bed for two days. Killing me to not be able to get started.

surfcowboy

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Re: Cowboy Foil Experiment Thread
« Reply #239 on: July 15, 2018, 04:26:36 PM »
I cut into my fuselage to start the repair.

I'm so unmotivated I almost started a new fuse from scratch  but it's now the principle of the thing so I'm gonna try to patch this one up and get it in the air.