Yeh It's nasty stuff, I will be out in the open air as well.

Is there a reason you didn't use Carbon fibre and/or innegra for the extra layer.They a lot lighter than glass? Innegra doesn't finish well but a light glass layer on top helps.

Select to expand quote

gregjet said..
Is there a reason you didn't use Carbon fibre and/or innegra for the extra layer.They a lot lighter than glass? Innegra doesn't finish well but a light glass layer on top helps.

I just bought the standard cheap fibreglass cloth. The weight in the board looks like going over 10kgs so a bit of extra weight won't make too much difference. I probably don't need the extra strength, it's just a waterproofing layer that I need. That Innegra looks like great stuff though.

took to the board with the belt sander and have cleaned up the rails. Which of course exposes all the imperfections that I will need to fill and sand back. The rails are really solid, no movement in them. Some of the honeycomb centre of the panels has been exposed in areas so I will fill those as well.

I managed to make the board with a single concave in the nose and a double in the tail. As I was making it I strayed from my design and cut more concave into the nose than I originally planned to. Now I'm wondering if I went too far as I have a Smik and a Naish that have less. Can anyone give an opinion on what this will do to its performance? I can probably fix it before I glass it.

Ok I'm back..
have done some more on this board after a few months of being too busy.
I have fibreglassed and epoxied the bottom and now preparing the top for The same. Only need one layer of 4 oz as it's already strong enough, just needs to keep out the water..

Glassed the top

Lookin good

Select to expand quote

andypoz said..




Glassed the top

Good job

What thickness did you use for the deck and ribs?

Crazy good

Well done! Now wondering how it will go.

Select to expand quote

Grantmac said..
What thickness did you use for the deck and ribs?

I have a couple of thicknesses in the panels, about 5mm and about 12 mm. The spine was the thicker one and I used the thinner ones for the ribs. Deck was the thinner one also. That was just based on what lengths and sizes I had available really and trying to use all the smaller off cuts, so I have more left for future boards.

Still need to sand both sides back, and cut a hole for the carry handle, leash plug and fin plugs. Then a hot coat over the top and polish it up.
I was planning to put a breather plug in and constructed a support box under the deck in the early stages. I marked the spot with a drill hole that I plugged up and could initially see, but now I can't find it..haha!!!
Too late now, I don't think it will expand as that panelling and epoxy are very strong.

I'm very curious to see how this construction holds up.
Are you buying whole panels or getting off cuts from somewhere?

Select to expand quote

Grantmac said..
I'm very curious to see how this construction holds up.
Are you buying whole panels or getting off cuts from somewhere?

I bid on these panels not really knowing what they were, thinking I could use them for frames for timber surfboards, they are left over from a luxury yacht builders yard, they build their kitchen from them after putting a veneer of timber over them. Super strong and light weight.
I was the only one who bid. When I arrived they asked me if I understood what I bid on. He said there was over $5000 worth on carbon panels, so I paid him the $14 that I bid and left.

That's awesome! I'd love to get a sweet deal like that.

Added a handle and leash plugs, two should be stronger. I put a patch of fibreglass over them for a bit more strength.

Love the rustic look of the board, hope it rips for you.

Added the 5 fin plugs, will reinforce them with some cloth after sanding them back.

Have applied a hot coat to the board. The bottom coat fish eyed a bit so will need to do another coat. So far the top seems ok. I never know what causes the fish eyes, probably dust in my garage, mayb temperature.

Wasn't a very easy build due to using rigid panels. Will definitely use the panels again but will use timber for the rails as it's a easier to form the curves. Came in at 13kgs, I was hoping for under 10kgs. I think I could make it lighter if I use less epoxy when gluing it all together. It's quite stable in the water, sits lower in the water than my other boards but I have put on some weight so this could be contributing. Will take it for a surf when I can.
Will start thinking about what to build.

Was very interested to hear comments on build process after you have done many wood boards.
Honeycomb carbon is an awesome material and combining with timber panels to make an easier build makes a lot of sense.
Great to see finished board and hope you get some waves soon