200 litres ,84 wide , 289 long .
Hopefully an improved light wind planer for heavy me .


13kg eps front half , 19kg eps back half.


3mm core on.



Glassed with peel ply squeegeed over the top.





Need wind.

The Neu one.. NICE. How did you join the two different density eps? Scarf join?

Scarf join , yeah , similar , PVA glue .
Your probably wondering why I build my boards sideways , its cos I need a challenge . Its great having a revolving garage . Freaks the dog out .

Very interesting.....

Thank you for sharing and great to see the quick build thread after seeing a teaser on 'sugar/sesame/crushed walnut thread'

Bit of length to build speed before planning and masttrack and strap location looking for good reach topend

Please follow up with brief review
Ps bit cold for windsurfing Auckland( unless you really keen for extra gusty wind, use the seasons for snowboarding next week ???????

How do you shape the foam?

I wanna know where are u getting that 10mm (?) EVA

I use a very thin finished size stringer for the rocker and thickness . Planer down to stringer .
A template for the outside . Sandpaper covered boards for bottom and concaves , then planer for top and rails. Lots of sanding.

Select to expand quote

Mark _australia said..
I wanna know where are u getting that 10mm (?) EVA

Its a secret
I make my own .
Its the normal 6mm diamond cut stuff which I glue to a 5mm lower density foam I get from Clark rubber . It only comes in blue. I cut it with the Stanley knife at 45deg. Then with scissors trim the edge leaving a 1 to 2mm side .
Ps . The under foam is not eva and is weaker than eva . It tares a lot easier. Cheap .
It is closed cell and sticks well with contact glue .
Pps , it's called Artilon ,$ 27 per m , 2 m wide . It's a PE foam. They call it high density, it's not , it's very light.

In the US, North Shore Inc. sells dual density EVA cut to size with or without adhesive backing, do not know if they ship worldwide.

I make my own dual density same as above but if I could find thicker (8-10mm) cut diamond EVA I would use it.

Select to expand quote

Manuel7 said..
How do you shape the foam?

Electric planer and / or Surform. Then shapers foam blocks with special rough "dots" sandpaper or sanding gauze, so it doesn't clog.
A autobody speedfile is very helpful too
Its easy with the right stuff but you could do a whole board with a Surform and a block with about 120grit

Thank you. Hand shaping at its best!

what is the lay up on this one. just glass no d cell or carbon or anything? the colours look good, what's the bottom look like, photo? you got a mini board factory going there where do you store all these toys

oh my bad I just saw you got 3mm core on there. does that go straight on the foam blank or glass first? Oh and I also wanted to ask you did you ever come up with a reason/cause for the spontaneous combustion incident?

Lay up is .
4 oz glass over blank top and bottom .
3 mm divinycell top and bottom .
2 x 4 oz glass on bottom .
Top 2x4 oz glass , one x 4 oz from in front of mast back, 2 x 4 oz under foot pad area , 2 x 4 oz under heels .
Extra 1 x12 oz and 1 x4 oz over mast track
6 oz patches over foot plugs and top and bottom of fin box .

Im sure the board explosion happened from re gassing of the expandable foam I used to glue sheets of foam together for the blank . ( three cans ). Do not ever do this ! As soon as I put it in the sun it puffed up like a puffer fish . If I knew this would happen , I should have let the blank roast in the sun before laminating it. After taking the top part off the board I left it sitting in the sun for a couple days before fixing it . All the gass is out of it now.
It was just a distant bad memory until you brought it up . If. I can just save one person from doing this , it is worth the pain .

Thanks for the build how hard and much did you work the peel ply.

Just tossing up if to bag or do what you did thinking likely not a lot of difference?

The peel ply didn't soak up much resin because I hand laminated quite hard . It did however leave a much smoother surface which hardly needed any filler .
If I had a vac system , I would definitely vac . I had to use a lot of thickened resin to stick the core down adding weight . A wet layer of resin is not enough to stick the core . Hand laminating as a guess would add around 20% in total weight . This 200 litre board is a smidge under 13 kg inc pads and foot straps . Same lay up bagged , probably 11 kg . Also bagging would stick all the layers together better .

Select to expand quote

Imax1 said..
The peel ply didn't soak up much resin because I hand laminated quite hard . It did however leave a much smoother surface which hardly needed any filler .
If I had a vac system , I would definitely vac . I had to use a lot of thickened resin to stick the core down adding weight . A wet layer of resin is not enough to stick the core . Hand laminating as a guess would add around 20% in total weight . This 200 litre board is a smidge under 13 kg inc pads and foot straps . Same lay up bagged , probably 11 kg . Also bagging would stick all the layers together better .

Cheers thanks for the info when did or could you remove the peel ply, when fully harden or before just thinking about a cut lap?

Select to expand quote

IFocus said..

Imax1 said..
The peel ply didn't soak up much resin because I hand laminated quite hard . It did however leave a much smoother surface which hardly needed any filler .
If I had a vac system , I would definitely vac . I had to use a lot of thickened resin to stick the core down adding weight . A wet layer of resin is not enough to stick the core . Hand laminating as a guess would add around 20% in total weight . This 200 litre board is a smidge under 13 kg inc pads and foot straps . Same lay up bagged , probably 11 kg . Also bagging would stick all the layers together better .

Cheers thanks for the info when did or could you remove the peel ply, when fully harden or before just thinking about a cut lap?

When hard the next day . I think it can be removed after it has properly gelled .

Select to expand quote

Imax1 said..
Lay up is .
4 oz glass over blank top and bottom .
3 mm divinycell top and bottom .
2 x 4 oz glass on bottom .
Top 2x4 oz glass , one x 4 oz from in front of mast back, 2 x 4 oz under foot pad area , 2 x 4 oz under heels .
Extra 1 x12 oz and 1 x4 oz over mast track
6 oz patches over foot plugs and top and bottom of fin box .

Im sure the board explosion happened from re gassing of the expandable foam I used to glue sheets of foam together for the blank . ( three cans ). Do not ever do this ! As soon as I put it in the sun it puffed up like a puffer fish . If I knew this would happen , I should have let the blank roast in the sun before laminating it. After taking the top part off the board I left it sitting in the sun for a couple days before fixing it . All the gass is out of it now.
It was just a distant bad memory until you brought it up . If. I can just save one person from doing this , it is worth the pain .

Sorry for bringing it up mate, I know it brings back bad memories but you have to make mistake to be great and collective knowledge is a good thing. It will save future pain and suffering.