10'4" Hollow Basswood /
May '03 -
Framework is Carbon Fiber reinforced...
The deck and bottom are Cedar/Basswood...
The fin is cedar/basswood...
Rails are laminated Cork and Bending Plywood. ..
Built to ride...
A few months ago Steve Pezman
approached me about building a hollow board for an auction benefiting Surfrider
foundation later this summer…I said sure…I’ll donate the labor if he
covers materials…A good deal…
Things had been progressing smoothly
on the 10’ hollow board…About 300 pieces and about 40 + hours of labor and
things were looking better than ever… The framework, deck and bottom skins,
rails had all gone great…
I laminated the bottom first, then the
deck using epoxy resin…I’m took a bit more time to get it just right…After
the deck lam was set up, I hot coated it with polyester resin…I’ve done it
before…It sand easier than epoxy...Next, I stuck the fin on…It’s looks
The next day, I move the board outside
for a few minutes while I clean out the shop, and when I get back to the board,
two bubbles the size of bars of wax have lifted the glass off the wood deck…NOOOOO….!!!!!!…..
I get the board back in the shop, make
a quick decision to perform emergency surgery…I grab the sharpest knife I have
and make parallel slits near the outside of each bubble…I press the glass back
down, and it seems to stick…Whew…
The following afternoon, I get back to
the board and one of the bubbles lifted again….GRRRR…no make that GRRRRRRR…I
don’t take a lot of time deciding what to do…I grab the belt sander, throw
on a 36 grit belt, really crank the stereo, and launch into a full deck glass
job removal…As I’m sanding I can smell the polyester fumes that have
softened the epoxy, causing HUNKS of it to separate from the wood…I’m
guessing that the epoxy needed to cure more fully before sealing it with
Two hours of intense dust, chunks,
sweat, and a belt sander repair later, the deck looks ready for some new
glass…Wow…The sanding was delicate at times…The surface wood is only
1/8” thick, so a heavy hand could have been less than groovy…I’m
After a few weeks of waiting for some
resin to arrive I’m back into the
glassing …I only have to re-lam the deck, hot coat, sand, and gloss…
So the resin finally arrives…I lay
out the cloth mix up a batch, and lam the deck…BUT, the resin is absorbed
un-evenly on the wood…Streaks of saturated and less saturated…And I’m
WORKING the resin…Nothing evens it out…I’m not going to re-strip the glass
again…I think the hardener was a faster hardener than the one I used in the
past, and it might have absorbed and set differently, I don’t know…The
visible differences are minor, and under a coat of wax it won’t be noticed by
anyone, but for an auction board, it won’t do…
I end up sending my first 10’4”
south for the auction…Ridden a few times…Cleaned up and polished it looks
great…Someone will be stoked to have it…
Back to the “problem child”, I get
the board hot coated, sanded and glossed…DONE…Looks fine… Ready for some
water time… WHEW…
Board 6 is in the
collection of Bloomingdales, California...
Board 6 is in the collection of Bloomingdales, California...
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