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Messages - kiwi

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46
Foil SUP / Re: Diy foil nz
« on: July 28, 2018, 01:43:06 PM »
Need to pot the tuttle head with the new tuttle adapter, does anyone know the best mold release between epoxy and aluminium, also the adapter has machining ridges on the radiuses and isn't perfectly smooth so im not sure how molding the tuttle head will go.

I use carnauba wax. Mostly because it's easy to get and it works. 100% carnauba is best. Used to be Eagle One had 100 percent in cans. the company was founded by my late best friend so I have a lot of the stuff around. I wax the mold or plug, let it haze, polish, then repeat three times.

Thanks pono

I've been using "Meguiars Mold Release #8" a lot with great results.  I can't say I've used it on aluminum specifically though, but I don't think it would matter too much.  However, I think that looks like the FoilMount CNC adapter that you're going to use as a mould, just like the one I bought from them too (but didn't use as a mould).  Feel carefully on the front and rear surfaces on the inside of the tuttle mount and you'll feel some machining steps in there.  Those may make it harder to release than a completely smooth surface like I've been working with.  You might want to extra wax up those micro steps so your epoxy doesn't get a hold in them.

I attached a pic of the steps...

(crap, I just noticed you were already aware of the steps, sigh...)

haha thanks sharksupper
yeah i've gotta somehow smooth those steps to stop the epoxy grabbing, I think If I hit the thing hard enough it would pop off anyway but not gonna risk it

47
Foil SUP / Re: Diy foil nz
« on: July 27, 2018, 10:19:44 PM »
Thanks surfcowboy for all the support :)

I bought one of those foilmount tuttle to plate adapter and some 10" longboard rails, yes I know they're no the glass filled plastic that chinook sells but theyll work for now this is just an experiment. I epoxied the rails into the box I made at work and then cut the hole in the board for it, the board is a little 5'3" we use for scurfing. It's pretty small and will be hopeless in the surf but I'm planning on building a board for prone foiling anyways.

I attached the wings to the fuz after I finished sanding them smooth. I used M5 helicoils to with stainless bolts to mount them and I hope this will be enough to hold them on  :-\

Need to pot the tuttle head with the new tuttle adapter, does anyone know the best mold release between epoxy and aluminium, also the adapter has machining ridges on the radiuses and isn't perfectly smooth so im not sure how molding the tuttle head will go.

48
Foil SUP / Re: Diy foil nz
« on: July 27, 2018, 10:00:50 PM »
Fuz all glued up, fits nicely with mast. Made quite a bit of progress this weekend so ill post some more up later.

49
Foil SUP / Re: Diy foil nz
« on: July 12, 2018, 01:09:17 AM »
Last week I cnc'ed the main foil with the same technique and set a 4mm plate into it for the countersink m5s.
Dad showed me how to glass the wings so they've now got a layer of 300gm biax and been bogged up. Gotta sand them all down now.
I've got access to the cnc at work (just a holiday job at a mostly polystyrene cnc place, theyve got a 5 axis tho  ;D ) and there is a whole lot of pvc foam laying round so I'm going to dig through it and find some 60kg stuff to do the plate mount cassette for the board.

Still gotta glue the 3 parts of the fuz together and get everything mounted together.

50
Foil SUP / Re: Diy foil nz
« on: July 05, 2018, 01:15:16 PM »
That is looking great Kiwi.

I like how even the pattern between wood and glue came out in the plywood.

For one-side flat surfboard fins I usually try to design with a minimum trailing edge thickness of .03"[0.8mm] and/or laminate cloth and resin to the flat side before machining. These two thing help keep the splintering to a minimum. I also just use small tabs to keep the part attached to the stock, like .250"[6.5mm] or so wide and .125" [3.2mm] thick.

Thanks jrandy
Yeah I think I'll include a trailing edge thickness next time because the splintering is pretty annoying.

These are great man. I'd definitely still glass the wings. Stresses are higher than you realize in certain areas. Don't ask me how I know. lol

But the cuts are so clean. Great to see those perfect lines laid out in the laminated layers.

Cheers surfcowboy
Yea I'm definitely still glassing the wings, the strength through the mid section is great but the last 50mm of the tips gets pretty flimsy. Will just glass the entire thing for the guaranteed extra strength.

51
Foil SUP / Re: Diy foil nz
« on: July 05, 2018, 01:51:24 AM »
Wow, that's some gorgeous fab work Kiwi.  Very interested to see where this ends up.

Cheers  :)

52
Foil SUP / Re: Diy foil nz
« on: July 05, 2018, 01:50:46 AM »
I cut the stab on the cnc the other day, a proof of concept for the main foil really. I needed a way to flip it on the machine and keep it from flexing under cutter load so I left a number of uncut support material tabs along the foil. Turned out to be plenty strong enough for the cutter load and it didn't take long to chisel them off and sand them smooth. Ideally I would have a female setup to fully support the material but since these are one off's this will be alright. Machining up the front wing in the next few days and show you all how its sorta going to look like once its finished.
Need to glass these wings because the trailing edge is way too flimsy. I have no doubt that they would be strong enough but it's just the trailing edge than needs some strengthening. 18mm plywood is a lot stiffer than I expected.

53
Foil SUP / Re: Diy foil nz
« on: July 02, 2018, 01:47:48 AM »
This is looking so clean. Coming along nicely. What's the total width of the fuselage?

Thanks man, total width is 28mm dropping off to 20mm for the stab.

54
Foil SUP / Re: Diy foil nz
« on: July 01, 2018, 11:15:51 PM »
Here some more photos.
Fuz construction is similar to the mast, plan is to epoxy the mast and the three sections of the fuz together with some fasteners through the middle to make one solid structure.
Next up is the stabilizer and the main wing :)

55
Foil SUP / Re: Diy foil nz
« on: June 27, 2018, 03:38:25 PM »
Does anyone have the exact measurements for the gofoil tuttle head?

Im looking into building an adapter similar to sharksupper's build.

Thanks in advance

56
Foil SUP / Re: Diy foil nz
« on: June 24, 2018, 12:47:44 PM »
Thanks Jrandy

The cutter I used is the key to using the cnc for glass plate.
https://www.amanatool.com/46099-end-mill-point-diamond-pattern-composite-cutting-1-4-dia-x-3-4-x-1-4-inch-shank.html

I run it at 1000mm/m at 1mm depth of cut and just set my spindle so it doesn't sound like it's struggling. This cutter is way more capable than this though, have at look at this video:
https://www.youtube.com/watch?v=Ucv3nDgmf3o

The plan for the rest of the foil is to use the same 4mm plate for the fuselage and then to use plywood with a layer of fiberglass for the foils themselves.



57
Foil SUP / Re: Diy foil nz
« on: June 24, 2018, 02:03:45 AM »
Ok here we go

58
Foil SUP / Diy foil nz
« on: June 24, 2018, 01:56:12 AM »
Hi all

Background story: I'm 16 years old and live in NZ, I've always been around and on the water and around 6 months ago I got hooked on foiling. The first time I tried it I was being towed around on a friend's foil behind their dinghy and I've been hooked ever since. I've since been on it every now and then but because I don't have one its hard to put the hours in to get good. Long story short I decided to build one.

I started work a few months ago with building the mast, it is made of 4mm balanced E glass plate laminated together to make up 12mm. I then put it on my cnc and cut out the Naca 0010 shape into it.

I'll post photos once I figure out how on earth to do so

59
Foil SUP / Re: Seriously thinking about quitting this sport!
« on: June 15, 2018, 01:49:02 AM »
Sheesh that sounds like it really sucks.
My friend's dad has gone through two maliko 200's in the exact way, one split at the head then slowly delaminating all the way down the mast, the other started showing stress fractures in the surface coat of the fuz and went downhill from there. He never took it out in more than 2 metres.
Sounds like these gofoils aren't built to stand anything.

60
Foil SUP / Re: Cowboy Foil Experiment Thread
« on: June 13, 2018, 03:39:36 PM »
Oh yeah you weren't kidding, those profiles are seriously fat, I'm working on something with a clark y 12% at the moment, not sure if that will be enough but we'll see.

Going to post it up to the zone in a couple weeks

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