Complete makeover of my unlimited.

[headmount]

I like your reasoning to do this.  What length for the remodel?

[PDLSFR]

Nice, keep posting your progress and it's cool watching this from start to finish !!

Great job, so Far....

[surf monkey]

Tall dude

Some crazy stuff,

I Liked seeing the weight after you stripped it makes me think of DW's way of glassing pre wetting out the cloth to save weight.

Are you still drinking beers?

[paddlejones]

Can't wait to see the finished product

[TallDude]

Ok, I finally got over the flu, and got some time to do some shaping!!! Here we go. As I approached the shaping, I realized the noise from my planer, router, etc. power tools was going to probably be to loud for night time shaping. Plus I couldn't find my hotwire. So I cut the shape and rocker with hand saws, scaped, filed, and sanded all with non-power tools.

[TallDude]

And of couse the shaping companion! As it sits, with the original carbon deck still in place, it weighs 16#'s. I'm hoping with a micro bubble sealer, one layer 4oz carbon fiber, and an extra strip of carbon fiber the full length of the rails will total another 6 or 7 pounds. 22# to 25# total is the target......

[DurhamSUP]

Great work. This is one heck of a project. I have to admit, when I first saw this, I thought 'why not just get a new blank?" But it looks like the shape worked out great and you saved the cost of a new blank and a carbon deck.
I think the tail needs a Bass label lam'd in the glass.

[raf]

Awesome project!  Very inspiring.  I've got 2-3 foam monsters in the basement...

Keep it up and post pics. 

[TallDude]

Ok. So I'm finally making some progress again. I'm ordering the carbon fiber cloth this week. If all goes well, I'll be glassing the following week. I ended up getting a piece of Divinycell foam to reinforce the fin box. The piece was 3/4" thick so I glued two pieces together to make it 1-1/2" thick. I Gorilla glued the rigid foam in. Then I routed out the fin box slot, plumb and lined the fin box, and epoxy'd it in. Next is some detail sanding (which seems to never stop) and spackle. I like using a laser to line everything up, and check my rocker. I wasn't that happy with the nose, so I reshaped it. I like it better now. I can see the end in sight.

[SUPCHLU]

Good God man, that's one heck of a project....

I must say I'm quite impressed TD!!

[TallDude]

Ok so I'm back at it. Finished shaping it. I spackled it, and sealed it with micro balloons. I know it's basically double sealing it, but after talking to Mark Johnson of Hobie ( another neighbor of mine. I love Capo Beach.) he said they learned early on that an extra 6 oz. or so is well worth it. The spackle and very thin epoxy w/ micro balloons, added 1 pound. I'm at 17 pounds as it sits. We start glassing tomorrow.

[PonoBill]

Very cool. I have a thoroughly trashed F18 with an internal carbon box that I'm thinking of peeling and reshaping. I'd like it a little narrower and a little rounder in the rails. Once I finish painting Dianes section of the warehouse that might be project one.

[punasurf]

Nice job!  Can't wait for the final result.

[SUPflorida]

Pomobill can you elaborate on the internal carbon box...does it hove a hollow box at its core wrapped with EPS?

[PonoBill]

Yup. It was a direction Mark tried some time ago but didn't follow up on. Semi-cusom hollow.