Diy foil builders

[scubasteve]

Any body thinking of making there own sup foil?
I am just posting a link, to inspire a few people....



Cheers
Scuba

[surfcowboy]

Have you not been checking the boards? There are 4 or 5 of us chugging away at it with various levels of success and skill. Check out my experiment thread, the DIY (SupUK), opie's build and then the mind blowing method of SUPPeter. Container seems to have been in it before any of us. And JRandy is invariably going to do something cool with his CNC.

Thx for the link. Dig in and check out all the various builds in progress. I think by year end you will see some real progress.

[jrandy]

Scubasteve-
Most of the stuff Cowboy is talking about is in the Foil SUP forum:
https://www.standupzone.com/forum/index.php/board,88.0.html
Lots of neat stuff for sure.

Thanks for your clip too.

I have stalled out on completing the foil, behind on other projects too esp my daughter's SUP for this summer...
Last pictures of mine are in the 'R&R' thread in the Shape Shack:
https://www.standupzone.com/forum/index.php/topic,33056.0.html

[scubasteve]

Thanks

These are the 2nd an 3rd boards n foils that i built in 2014.
For kite surfing.
Just making another mould for my sup foil, and finishing the 3rd sup board.
Once you start its hard to stop...
All protects,  not my job.
Cheers
Scuba 

[opie]

One of Scuba Steves' posts was the source of the plywood method I used to add tracks to my board.  Thanks for that.

[scubasteve]

Your welcome Opie.
I have not had a board fail with that method, and i have hit a few sand bars flat out on a kite (47kph).
Happy to pass on tried and tested ways of doing stuff.
 

[surfcowboy]

Steve, isn't know that this was your build. That's awesome man. How did you make your molds?

Please post up your project. I think we're all still trying to work out the best way to build these things.

[scubasteve]

Thanks SC

The way I make a mould is as follows:
buy your self some balsa wood, lets just start with the mast, so if your mast is say 16mm thick at the thickest part, then you would need 2 x 10mm thick pieces at what ever length mast you are making say 700mm.
You need to glue them together temporarily with about 3 dabs of pva glue smallest amount of glue.

Once the glue has set and you have a mast of 20mm x 700mm x chord ..? 120mm
Draw a line on both sides of the mast for the foil normally about 30mm from the front to sand too then shape your mast, easy as with balsa.
Then do the same for your fuse, if you have a 30mm thick fuse  you will make the thickness out of 4 x 8mm pieces. Right, important super glue is locktite 401 or 406 and it sticks balsa together in seconds and will not come apart.
So glue 2 pieces of your fuse with super glue and then glue both pieces together now with 3 dabs of pva that it makes up the fuse thickness.
Then shape but be careful where you want to join the mast to the fuse has to be flat for the gluing.
Hope you havent lost interest yet?

Right next you would glue the mast to to the fuse very carefully glue with super glue being carefull not to glue both sides to together, so half of the mast thickness gets glued to half of the fuse,both sides.
Now the the mast n fuse are glued together you can carfully split the the thing down the middle where you have only put dabs of pva, simple right?.
Now you have 2 plugs to take a mould off.
Just like the video.
Cheers
Scuba 

[surfcowboy]

SS, thank you. Hadn't thought of using balsa instead of foam. This is great. I'm definitely trying this for my next setup. Also making a mold makes it easier to make dupes for friends if you get a good one.

What layup are you using for the masts? As you may have read, I recently proved that really only the carbon matters (lol) but I'm at about 9 layers of 6 oz and wondering if I should go more if I don't have a plywood core.

[scubasteve]

For the mast i have in the past used twill on  the outside then layers of uni, double bais all of about 7oz or 200gsm.so solid carbon.
But have learnt that all the strength is is the outer layers of 3 or 4mm.
So you need to put twill,bias and uni to a thickness of around 4mm then put either a wood core or fill it up with layers of glass.
The new build i am working on will have a ply core in the mast for wieght reduction and boyancy, but the fuse will be solid carbon.

[surfcowboy]

Thanks man. That thickness sounds about where I was guessing. 4 mm would probably be around 12 ply of 6 oz carbon. (I'll need to test that.)

Seems like figuring out a lower density and weight pourable fill with a little structural strength would be a good project for this board. Gotta be something we can find that's lighter and stronger than wood and not super expensive.

I'm going to have a hollow wing for my next build and it's got to get filled. Pour foam works but I'd love just a little more strength if I could get it.