Base Plate to Mast Construction

[Surfside]

Hi, currently assembling the mast, fuselage and base of a Clearwater kit. I routed a 1/2" deep recess into the fuselage at the mast connection added around 50oz of cloth to each side of the base/mast and also drilled and epoxied 2 1/2" x 3/8 fiberglass rods. More glassing in that area will be applied when I glass the fuselage. I hope this is stout enough. My concern is how to beef up the mast base connection.

I would appreciate any and all suggestions

[jrandy]

We've been discussing this a little on Cowboy's 'Experiment' thread in the Foil forum.

I did mine as a hole in the plate 1/32" per side larger than mast.
There are 4 layers of cloth (3@7.5oz+1@4oz) with resin per side setting the mast into the hole.
Next to happen is a fillet of resin+spheres (filler)+silica(anti-slump).
Cloth and resin to follow making a smooth transition over the fillet.
I am not finished so no long tern reliability to report.

[surfcowboy]

Man, father you have the rods, epoxy, a recess and 50 oz of glass, you might not survive the crash that breaks that lol.

I can't speak to it from experience, like any of us, other than SupUK or container but it seems good to me. I'm at 30 oz of fabric (18 carbon and 12 glass) and it seems like it's gonna be ok. I know those kits aren't ply so it's probably good that you made the glass a little beefier but it seems like most folks with those kits aren't going that heavy. What does the maker suggest for a layup?

I'm anxious to see how that flies. Are you putting it in the surf?

[Surfside]

jrandy, I was thinking about constructing that way also, great diagrams! Thanks Probably do it that way. The other option is to use a fiberglass joint biscuit or more fiber rods.

surfcowboy, here's a scan of the directions....
I plan on attaching it to an old wakeboard with boots to become more familar with the foil before going in the surf. These wings have sharp edges and I believe a modification/or new set for the surf would make me feel more comfortable.

Thanks

[Surfside]

The wood was so light that it cracked while connecting it to mast. Plenty of glass for this area. Should be done soon

[jrandy]

WWR-Sorry to hear the base split.
I ended up using a higher quality plywood ( 9 ply 12mm) for my base and the hole was about one layer of 4oz 'loose' of a hammer-in fit.
In retrospect I wished I would have wrapped the mast before assembling it to the base...but it is so tempting to assemble pieces to see the form come together.
I'd put at least one piece of cloth each side on the 'bias' (45 degree warp and weft instead of parallel to the plate/mast/board/).

[Surfside]

Hind sight is 20 20. I should have put a layer of glass on each side before cutting. Oh well, the crack is stronger than the rest of the wood. The black outline seen in the pic is 20 oz of carbon and 18 oz of fiberglass already laminated to the mast.  I also should have slid a 20oz piece of carbon cloth down the mast to the fuselage to use for a final glassing of the base for appearance. Kind of like this pic of 20oz waiting to be epoxied to the fuselage.

[surfcowboy]

Hey man, did you ever get this thing flying?

[Surfside]

Hi Surfcowboy,
I flew the wings on another mast with a tuttle box so I could windsurf with them. They worked, but they tend to slip sideways during a turn.

This was for a friend who never took it and is still not sure he wants to foil. Since then, I acquired a broken Go Foil fuselage with an IWA and 200, fixed it and been having a blast in the surf and behind the boat. I plan on leaving the Go Foil at the beach house and attach this mast to either an old wakeboard or build a behind the boat board for it. Here's a shot of it with other wings. I'll post a video or pictures of it in action in the not so distant future