Shaping a polyurethane foam fibreglass surfboard

[skeghead]

Finally started work on my favorite hobby. I am on a facebook page for backyard surfboard builders, but find it too intimidating. :no:

I feel more comfortable on this forum. (I have worked previously as a carpenter)

My quality and shapes aren't great, but I love the process. They have a face only a mother could love. :D

Shaping stand and basic shape rough out.

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[crowie]

Looking good :2tsup:

[derekcohen]

Are you using templates for the profile and rocker lines?

What tools are you using to shape the foam?

Are you vacuum bagging?

Regards from Perth

[skeghead]

Hi Derek,

I do an outline on one side using a flexible length of material to give me a curve, mostly using my eye and the width and curve that I want/like. I then cut the shape on one side of the blank. Then I used a sheet of cardboard to trace onto, cut the curve in the cardboard sheet and used this to do opposite side of board. With modern blanks the rocker is already inbuilt, unless you have a specific desire for a rocker type. I just use as is.

It's a board for myself for fun, or if someone likes it. So I'm not bound to a rocker profile.



Previously I used an electric planer. But this time I am going to try to do the whole board using a surform/s and sanding pad. I want to keep the thickness and using the planer cuts too much foam. A small block plane is required to cut down the wood stringer level, as you sand down the foam.


I have no experience with vacuum bagging. But it's not required with a polyurethane/fiberglass board.

Glassing process I use one sheet of 6 ounce cloth on top (for strength) and 4 ounce cloth on the bottom (keeps it lighter). 1 laminating coat and a filler coat and sand finish.

I have a set of fin plugs, but with this one will use 3 fixed fins this time. ( I have a set I rescued)

Thanks :2tsup:

[skeghead]

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:2tsup:

[Keith_1]

Great stuff.:2tsup::2tsup::2tsup:

You are a class act. :2tsup:

Many many many years ago when I shaped some boards, I used an electric planer as well, but then also progressed to a surform. Better control of how much you remove.

Looking forward to your glassing.

Keep up the great work

Regards

Keith

[skeghead]

It will be a slow build. patience is a virtue :wink:

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[skeghead]

not roller :wink:

pic 1 is deck up looking nose to tail. pic 2 is deck up looking stern to bow. :D

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[skeghead]

Looking forward to your glassing.



Still a way off yet till glassing stage, but,

Considering adding (green?) pigment to bottom layer or spraying the blank in an abstract way.

Adding a pic (stencil or hand drawn) onto the top deck, such as attached, for fun. :wink:

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[skeghead]

Keeping wood stringer flush is not so easy, need a really sharp block plane, otherwise it tears wood and foam. :no:

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[skeghead]

pick up Saturday :hpydans2:

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[skeghead]

ready for final sanding :)

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[skeghead]

costs for a board made from a 7' blank.

blank $80

fibreglass resin cloth and hardener $150

set of 3 fins including plugs $45

$275 excluding delivery costs

[skeghead]

I joined and posted on the backyard shapers facebook page also. feeling more confident. :)
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[skeghead]

bottom ready for lamination resin mix. :;

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[skeghead]

mix gelled early on me :oo:

some sanding to be done :C 495044
read glassing advice after the fact, ie use 1% mekp for lam coat. (I used 2%) :doh:

I need a hug :D

[skeghead]

used 800 ml resin 10 ml mekp. that's above 1%. for that size board, I would use 900 ml in future. not much wastage.

still ran out of time. :C

but a better result. :2tsup:

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[skeghead]

looks OK (prep work and catalyst/resin calculations very important) :)

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[skeghead]

done :2tsup:

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[q9]

Keep strictly to manufacturers mix ratios, and if you feel adventurous, try an epoxy - you can get all different cure rates, but again, stick strictly to the supplied ratios.

I never really liked using MEKP, but it is cheap and well understood.

[skeghead]

sanded fibreglass by hand 40-80-120-180-240

recycled some fins and tacked on with epoxy glue ready for glassing on :)

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[skeghead]

fins attached, sanded to 400 grit. put my name on it. :;

Finish coat and leash plug to complete.

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[skeghead]

Removing fibreglass from an old board I shaped 10 years ago and reshaping. Going from 8' to 7'.
Left side showing new planshape. :wink:

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[skeghead]

now to clean it up :)

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