Project Board 2016~17 , hopeful on date may be 2117

[U2U2U2]

From this I hope to make a FSW, of about 230cm X 64 and 105liters, key about. Materials Kevlar, carbon,S-Glass ,E Glass 6oz, E Glass 4oz. New USBox,slot boxes , ProBoxes, from a donor board, going to the board in Paradise playground, masttrack , footstrap boxes, feels good to recycle those $75 parts . CoreCell A80 6mm will be the sandwich on the bottom, the top will have S/E Glass, Carbon and Kevlar (yellow in the photo ON table) is reinforcement areas as needed. Inner core is EPS 2lb, heavier than most, judicious use of epoxy and materials will hopefully keep weight down. This is a major issue weight, I learned alot from previous projects.
I was lucky to find the EPS local, even more to the shop having a basic CNC machine. We input dimensions and about 25% will be shaped away.

Vacuum all larger areas. West Systems 105 epoxy.


Major advise from many sources, unnamed here, but noted so I have someone to blame.

[swchandler]

I have to ask, are you planning on using divinycell or other type of hard foam on the deck? Seems to me that it would be a mistake to omit it. I'm thinking that it's a bit of a chore to bend and craft it around the board's rails, but it really gives the kind of barrier strength in conjunction with different cloth laminations to protect against easily dented and damaged EPS foam.

[U2U2U2]

I don't do most projects archetypical . If I were building to resale I would do the typical sandwich. Several companies Goya, RRD , are discovering, that using SGlass is less costly than carbon, and doesn't suffer from concussion , being more resistant. It offers a smoother ride.

The deck will not have the denser core material , the mast , area between footstraps , footstraps will be reinforced, I may inlay core cell or use carbon/ Kevlar.
The EPS is 2lb, this is 1lb more that most density. Because mostly its what was here, difficult to rationalize a $99 blank and 75--100 to ship it.

This is not going to make sense to some, others have said it makes great sense. I'm not building a board , in the most complex manner, to last for years, in fact it may not work very well at all. Having gathered the data I need to shape to the size I want, I feel it will be ok, brilliant..
Have to see

[U2U2U2]

Photo test..

[rollerrider]

2lb vs 1lb to gain indentation strength doesn't really help much at all. Ive tried it. Still needs a sandwich layer of PVC or bamboo and after all that it weighs too much. The best and lightest boards hands down are 1lb core with double PVC sandwich with wood and or kevlar and carbon reinforcements. You must use a sandwich layer on the deck all around the foot stance area or it will get soft and delam there.

[U2U2U2]

Building with 1 lb EPS CORE and a full sandwich is only 1 way , and complicated.
I think using a semi sandwich board using 2lb eps, not dissimilar to Mark Stones SSD boards (albeit he uses PU foam and polyester).

2lb foam is much much easier to shape, doesn't need a full sandwich and (despite your comments) doesn't suck up water too quickly. It takes up less resin (so doesn’t need a heavy bog mix), supports the high density inserts better and I think is perfectly valid for a home builder first time project.

No the board wont last a life time.

Since EPS comes in .75 up to 2.85 lb density, the difference between 1 and 2 lbs your thought on strength not helping much is not consistent with my thinking.

The best and lightest board is not going to be the first attempt, at a total build, coming from a shed in Colorado, nor have I said as much.

I could show , as it sounds probably like you have seen yourself the 1 lb versions commonly produced, in halfs or with soft decks.
Appreciate the comments, really.

[U2U2U2]

*CORRECTION***
To above, have now seen EPS in 4lb, PCF.

[jp5]

Well I for one am very impressed with your abilities.

[U2U2U2]

[jp5]

No man I'm serious. Any board I'd make would end up in the fire pit some day.