[Mark E]

So I have started making a new board and since I have had a few requests from people to post pictures of the
process I am going to post them as I go along. I have no idea how long it will take but if my work load is not to
high I hope to get it in the water by the fall.

It is going to be 9' 0" x 22" x 2 7/8".  17" nose and 13 3/4" tail.

No concave in the nose but two concaves from the halfway point to the fins. 1/4" vee out the tail.

2+1 fin setup.

Today I hotwired the blank, tomorrow I will cut the outline and turn down the rails.

[PTSD]

I can't wait to see it unfold.

[Mark E]

Ok I am off to a good start, worked on the board most of the day, stopped for some world cup action but worked pretty steady.

Cut out the outline with my jig saw.



Split it down the middle with my trusty shark saw.




Then I glued in one of the rocker templates for a stringer.



The stringer is needed to hold the blank stiff while I shape the blank.

Next I busted out the planer and mowed some foam. I am not a shaper so I find this part the hardest.



Here is a look at the outline of the shaped blank. I put in concaves either side of the stringer running from the middle out to the where the fins will be.



So far I have $25 and about eight hours invested.

[SeaCliff]

Absolutely fascinating. Keep the photo journal of this going!! Can't wait to see the pics as she develops, and def cant wait to see her in the water!

 

[UNCLE!!]

Damn!!

Yes, Keep it coming!!!!

[PTSD]

Mark bro, your insane, its like a magic show to me. I love it.

[Harry Balzsac]

Nice work Mark.  Question: do you have to vent this board?  Is it 2lb EPS?

[skSURF]

Nice work Mark.  Question: do you have to vent this board?  Is it 2lb EPS?

I think you have EPS and XPS confused. Somone correct me if I'm wrong. EPS is made of small pellets held together and will absorb water. XPS or extruded Poly is a consistent block of foam.The XPS does not absorb water but does trap gasses that expand when heated. XPS boards have to be vented to prevent the expanding gasses from causing delamination.

[Mark E]

I think you have EPS and XPS confused. Somone correct me if I'm wrong. EPS is made of small pellets held together and will absorb water. XPS or extruded Poly is a consistent block of foam.The XPS does not absorb water but does trap gasses that expand when heated. XPS boards have to be vented to prevent the expanding gasses from causing delamination.

I am using 1lb EPS, XPS has its own problems. The air in EPS foam can move around the gaps between the beads so you can put the vent any where on the board and it will function. You also have to seal the blank before glassing  otherwise it will draw in resin and dry out the glass before it cures.

[surfnli]

mark--would you mind explaining hotwiring a bit more?  i see the wood/wire contraption, and i see the blank before and after, but i have absolutely no idea how you used one to get the other.  cheers on this thread!  great to watch the process 

[boyeee]

mark--would you mind explaining hotwiring a bit more?  i see the wood/wire contraption, and i see the blank before and after, but i have absolutely no idea how you used one to get the other.  cheers on this thread!  great to watch the process 

i am assuming it just heats up the wire and slices through the foam making a nice smooth cut as apposed to taking a saw that will leave the edges rough with foam flaking off?  correct??

[Mark E]

What boyee said. I screw the rocker templates either side of the foam block and the hotwire follows the outline giving me the rocker and deck profile.

[HydroGlide]

Cool.  How do you seal it before glassing?

[Harry Balzsac]

I've heard most guys use spackle (the creeping evil) thinned w/distilled water.

[Mark E]

I've heard most guys use spackle (the creeping evil) thinned w/distilled water.

I use light weight spackle with tap water. I don't have to worry about water stains because I am covering the board
with veneer.