Saturday, 29 August 2015

Board Building Project - HD Creeper 48 - Stage 8 - Clear Coat, Pads & Non-skid

Time for the final clear coat, sanding and non-skid.  I will keep a matt finish which shows the weave when wet - just like the finish on fins.  My non-skid was late night inspirado and I already don't like the waistcoat looking front - this will change down the track.  Also had a bit of trouble with the non-skid fisheyeing over to 1200 finish underneath - another experience for the memory bank.  This will be the last clear finished board I do, opaque sanding coats are so much quicker to finish.

 Clear coat, none under the pads to save weight.

 
 Clear coat tail.

 
 Wet and dry of the clear coat.
 
 Wet and dry finished.

 
 Pads and non-skid finished.

 
Hull sanded.

 
 Nose clear coat.

 
 Finished tail.

   
Ready to Rock.

Board Building Project - HD Creeper 48 - Stage 6 & 7 - Hull & Deck Lamination

Deck is bagged(200g Twill carbon, 130g plain glass + patches) and initial sanding is almost finished. Next up is to fill a few low spots I should have filled before glassing but couldn't be stuffed, then a finishing coat for polishing.

I glassed(2 x 130g plain glass + patches) the hull old school(not bagged) and everything was sweet until some gassing of the dcell combined with some crimped glass to form a few bubbles.  Yet more repair work.  The newer surfboard glass(130g) seems to use smaller glass bundles(and have larger openings in the weave) which leaves more resin on the layup table.  I think the layup might have been on the dry side as a result which doesn't help.  I probably should have glassed the hull on the board then feathering the 2 layers around the rail would have been easier.

There are a few tricks I tried for the hidden (under carbon) inserts which worked well.

 
 Deck Laminate Vacuum Bag

 
  Mast Track Bagged

 
Tail Bagged

   
Unwrapping fun!

   
  Deck Weave
 
Footstrap Insert Plugs revealed

Footstrap Insert Plugs sanded flush

Footstrap Insert Plugs flicked out

   
  Deck lightly sanded (sacrificial glass layer on top.
 
  Deck Sanded

   Deck Sanded

 

Sunday, 16 August 2015

HD Creeper 83 - Sneak Peek

Here is a sneak peek of my latest board build. There will be more detail to follow...

Its an 83cm slalom which is a bit of a Frankenstein with bits inspired by this and that.

The final design is a development of this design I was working on almost 3 years ago - http://whitelionwindsurfing.blogspot.com.au/2012/09/board-building-project-hd-s82.html

 
HD Creeper 83 Cad Model - Perspective

 
HD Creeper 83 Cad Model - Plan and Side Elevation
 HD Creeper 83 - Toolpaths

  HD Creeper 83 - Mowing Foam

 HD Creeper 83 -Foam Side

Monday, 10 August 2015

Board Building Project - HD Creeper 48 - Stage 5 - Inserts

Foot strap inserts, track, box and breather base are in.


 Marking out the fin box.

   
 Fin box router template.

   
 Routed Fin box on hull.

   
 Fin box trimmed to deck line.

   
 Fin box flush with hull.

   
 Foot strap inserts dry fitted.

   
 Edge of foot strap holes chamfered for glass wings.

   
Inserts fitted and glass wings taped flat.

   
 Goretex vent base fitted.

   
Tape removed and filler applied. 

Tuesday, 16 December 2014

Board Building Project - HD Creeper 48 - Stage 4 - Deck Sandwich

Well I have been meaning to finish off this series of posts on the Creeper 48 build but one thing led to another and I haven't! Comments are from the my seabreeze post at the start of the year during the build.  Creeper 58 coming soon...

I have got the tricky stage out of the way, now I can sleep easy not having to worry about the vacuum running all night. Tried out the aluminium clamping system on the bag and it worked a treat although it is pretty tight with 2 x 200um sheets/1 tube. I used 12x12 channel with 6mm PVC tube. Next up are the fittings...

Using up scraps, 3mm plain on the left, perforated on the right. 


Pre-forming the Dcell with a heat gun. 


Softened the winglet for continuity of the sandwich, will restore the wing with filler after the deck is laminated.


Tail panels fitted so that they can support the deck sandwich from below. 


Gunking the rails for the Dcell wrap.  


Fitting the bag and critical rail join. 


Flipped over in the morning with the heat lamps on - bit of a cold spell at the moment with nights in the low 10's.


Bag seal with 12mm channel and 6mm ID PVC tube. 


Deck sandwich trimmed with the snap-off knife blade.  


Finished composite Dcell deck - no more scraps left, just in time as my bulk shipment of Corecell and Dcell has just arrived for the next 3 boards! Love it!

Monday, 7 April 2014

Board Building Project - HD Creeper 48 - Stage 3 - Shaping the Deck

I am not one to rip into full length cuts using a plane, I prefer to mark out the rails and hotwire them. I like to create the hotwire guide lines from the CAD model and these allow you to remove the bulk of the deck roll and rail while maintaining a smooth flowing shape.  The faceted faces on the rail are then fine tuned with a sanding block with 80, then blended/rounded using 80 and then 120 grit. 

If you try to shape only sections of the rail to the finished profile you will end up in all sorts of trouble and it will show on the finished board - there will be really bumpy highlights and reflections.  I like to create construction geometry around the rail profile at various intervals along the length of the board.  Then I create some tangent lines at key angles and extend these to what would be the outline of the EPS block.  The position where the tangent line meets the block is marked and all the matching tangent - surface intersections are joined along the length of the board using the outline and rocker templates as giant french curves.  Using these curves also helps the volume flow nicely as you are using the same curves with which the outline was cut. You also need to mark the wide point clearly to allow the rail tuck to be shaped correctly.















So I went to shape the lower rails(below the wide-point) and found I had made a error on the tuck calculation - I allowed for the 3mm shell on the outline but not on the pre-cut 6mm Dcell on the Hull. I ripped off 3mm from the wide-point with the router, squared them up, re-marked the wide-point and re-blended the rails.  The Dcell hull was trimmed with my tuck template using a snap-off knife.   



Next was the deck concave which was originally going to be 3mm, I changed it to 6mm.   The mast track area steps down an even 2mm from the hot-wired deck.







Next up is smoothing the rough sand and fitting the deck sandwich.