May '04..
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Description:The deck / bottom is Styrofoam...The fin is flex fiberglass-removable...Rails are laminated Styrofoam...Carbon Fiber reinforced Styrofoam stringer and inner rails...Carbon Fiber laminated on inside of deck / bottom...Exterior Glass: Resin Research Epoxy /4.5-oz. Carbon Fiber Cloth- Deck x2- Bottom x1-Color coat laminated in 1 layer of 4 oz. e-cloth, top and bottom-Blue Imron paint on deck... Bottom wet sanded to 400 grit.....Built to ride... What I'm doing is making another hollow board... The frame and skins / rails will be made out of Home Depot blue Styrofoam... The "stringer" was planed to 1/4" and carbon fiber laminated on both sides...Then drilled out... The cross ribs were planed to remove the slick factory finish "skin"... I think it needs some roughness to get a good bond, even with epoxy... The cross ribs are laminated on both sides with plain fiberglass, and epoxy...Then drilled out... The outside rails are two layers of 3/8" Styrofoam laminated with a single layer of fiberglass/epoxy between them... I added another layer of foam between the cross ribs to keep them in place... The outside of the rails is laminated with a single layer of carbon fiber/epoxy... I "shaped" the inner layer of foam a bit... The 9' frame assembly weighs 1.5 pounds... The deck and bottom will be Styrofoam planed to 1/4", carbon fiber inside and fiberglass outside... I think the thinness of the foam will resist denting / crushing... The experiment continues...
This is the inside of the nose…Carbon fiber and blue foam…
The brown stuff is polyurethane construction adhesive…
The tip of the nose is reduced to allow the vent to have plenty of room to “breathe”…
Here’s the fin box…Mounted to the inside of the board, fully encased in Carbon Fiber…
The white strip on top of the box is a foam filler that replaces the stringer…
The shaping is done...Shaped Weight - 7.5#
The appearance is not a concern, since it'll be glassed with Carbon Fiber...
The bottom is laminated with 4.5oz. Carbon Fiber cloth and Resin Research epoxy...
Under the surface is an 8" wide strip of CF over the "stringer"...
The bottom is laminated...
I'm using 4.5 oz. CF to glass the outside...The 4.5 oz. CF's weave and ability to hold resin is much more like 6 or 8 oz. fiberglass cloth...I guess the actual weight of CF is less than fiberglass, therefore the bulk of the CF is greater, given an equal weight of cloth...I'm stoked on the strength of the CF, but a flyweight board, this will not be...The foam hollow is completed…To cover over the black CF cloth I laminated a layer of 4 oz. e-cloth to the top and bottom using polyester resin tinted green...Over that went a tinted fill coat, then finally a tinted gloss coat was added...It takes a lot to cover over black...The deck was sprayed with light blue Imron paint, then a black pinline was added at the rail line...
Board 8 is in the collection of Paul Jensen