Josh's board... almost done pics...
 

She's done.

http://www.floridakiteboarder.com/pi...oard/josh1.jpg

Looks nice Tom!!!

It looks pretty nice
Any idea of the weight once done ?

Around 100oz or less typically ... (just over 6 pounds). This board is smaller than what I have been making and it has carbon fiber / kevlar so it might be even lighter.

looks sick..

can't wait to ride it.

Very nice looking board so far, Mind if I pick your brain a bit.
What did you make the core from?
what material and how do plan on doing the rails?
what will your layup consist of?

Good luck, Kitespear. :)

Trade Secrets Huh?:rolleyes:

Just trying to learn as much as I can about all that I can. I made a nice lightwind ply board, And now I would like to get into "real" board making. It's passes the time on these windless days and combines two of my loves, Kiteboarding and Art.

divinicell + fiberglass + carbon fiber cloth & epoxy resin, half bag vacuum method. Rails are cast and lighter than ABS.

Finally got some time to install the inserts yesterday, I'll probably have this board finished sometime this coming weekend.

Thanks Tom,

Would you be opposed to letting me watch you work sometime. The whole process is a bit confusing.

Top done, outline has not but cut out from flash yet. Top came out perfect!

http://www.floridakiteboarder.com/pi...board/top1.jpg

http://www.floridakiteboarder.com/pi...board/top2.jpg

You know the old saying, for repair work:

$25/hr flat rate
$50/hr if you call before it's done
$75/hr if you watch

I'm kidding, but if you are serious about making boards I can offer some help. Only do it if you have time and money to burn... (or you are completely obsessed with building things yourself at twice the price).

Looks kick ass Tom. 3 more and people will be wondering why they are paying 800 for other customs. :)

I didn't see it at first, and thought they were blems, but that is your reflection, camera in hand, the street light and 2 powerlines, and a tree line in the reflection, nice.


http://www.floridakiteboarder.com/pi...board/top2.jpg

Yeah that's my reflection of my holding a camera.

It's back on the vacuum table. It's going to be finished today! Whooot!

Josh I am keeping the board! (kidding)

This board has no graphics... I'm still trying to perfect my process. Josh likes stickers anyway :D

Next board gets custom graphics.

I've always been wondering. I am still wondering.

nice! can't wait to ride it!


yeahh I'll sticker her up good.

Took a nick out of a @#$@#$ rail with my router :mad: @#$$@. But, still working the rails anyway so I can fill it in and it'll be fine. Just pissed me off.

Anyway here are some pics. Rails are not yet shaped.

http://www.floridakiteboarder.com/pi...ard/gloss1.jpg
http://www.floridakiteboarder.com/pi...ard/gloss2.jpg

Weight without straps is 75 ounces (4.6 pounds)

Tom I feel ya.... well, not literally... unless ya ask nice!
Don't ya hate it when you are routing and the edge gets thinner so your bushing guide slips off and ya cut right into the board.
I have about 5 boards that are 1/2" thinner than they were designed because of this.

Board looks sick!

Looks awesome.
Is there only one hole per fin?
I think UG use to have one hole on top and two dimples on the bottom to secure fins. Is that what you are doing?
I heard Josh doesn't even kite anymore. :)
Maybe I should take that off your hands.

http://www.floridakiteboarder.com/pi...ard/gloss1.jpg

Argh. Well I got lucky, the dig into the rail was actually pretty minor once I trimmed everything up and shaped the rails. Did not need to do any fixes.

Here are some better pics from a real camera (instead of a cell phone)... the top is not bumpy it's just how the carbon/kevlar looks because it's not perfectly straight lines... it's diagonal instead.

http://www.floridakiteboarder.com/pi...rd/gloss3s.jpg
http://www.floridakiteboarder.com/pi...rd/gloss4s.jpg
http://www.floridakiteboarder.com/pi...rd/gloss5s.jpg

Yeah I only drilled the center hole. I think I am going to drill out the others half way (like the old undergrounds) and if josh wants to use standard fins all he has to do is drill them out from underneath. Pretty sure 3 holes will work with either type of fin.

@#$# I want to keep this board REAL BAD. :D :D

But I am curious to see if Josh will ever break it (assuming he likes how it rides.. if not no big deal). I have serious doubts about it breaking.

Well. It seems pretty obvious you can build a board now.
If you start to nail the flex patterns and get that dialed, I won't ever buy a board from anyone but you (seriously).
Nailing the flex is probably 50% of how the board feels, I bet, in terms of pop, softness of landing, etc.
What do other board makers say about that (flex idea) ?

Looks awesome.

what kind of router set up are you using? template with bottom bearing?

that board looks sick! sorry tom unfortunately i'm about 99.9% sure i'll like it :)

I got a 555 120 for christmas, wonder which one i'll ride more.. i like the 555 alot, but it could be better, i'd rather ride my old 122 ug any day over the 555.. so we'll see..

well i guess i'll actually put these cabrinha stickers i have so much of on something now! lol

Galego:

Yes, but for the last time. I now have a better solution.

Scott:

Flex softer ride, better in chop, softer landings, softer pop.
Stiffness, fast, a LOT of pop, will slip out in chop if overpowered.

This board is on the stiff side. The tips came out a lot thicker than I had planned because of the thickness of layup, which made the board on the stiff side. Since Josh rides mostly flat water and does a lot of unhooked wakestyle tricks he will probably like the extra pop.

Josh, Hey if not I honestly am not going to be hurt. I learned a lot of new tricks (and a few mistakes) making this board and it was a fun build. Besides it's a free board :)

Fortunately I did not have to pay for the $70 piece of Kevlar/Carbon on the top of the board ... that was a gift from Bob.

Forgot to add it has a lot of concave and very mild rocker. It's gonna be fast as hell.

hopefully we get some wind very soon and i can ride it!!

Been there done that. Cursed like a sailor. Actually my router is such a P.O.S. (craftsman). There is a lot of play so when I push the guide against the template, the router bit will actually dig INTO the guide! After one board the guide is completely ruined.

Plus the kevlar/carbon in this board completely destroyed my 1/4" router bit.

tom, im a cabinet maker and i have many multiple tool including routers (porter cable)so if you want to use one just let me know.

Cool, I really appreciate the offer. But fortunately Colin built me a mini CNC machine for shaping blanks. From now on I will be shaping by computer. This will be great because I'll be able to do 20 blanks in one day, all exactly the same.

iv seen what a CNC can do for a cabinet shop and i imagine that it will just as good for shaping your boards. post some pics of it in action next board you build.

Hey Tom, been checking out the progress and have to say that is the nicest board I have ever seen. I ride Crazyflys and really like the snappy feel of the carbon.

Used to have a 127x40 CF that I put a small crack in. I was told that particular size was the only one to break. I still rode it for about a month before getting a 132x44 CF. Sold it for $50 to a light guy who wanted to fix it.

Anyways, both the CF started out really stiff, then after some riding "softened" up a little and seemed snappier. You think your board might do the same?

With the new CNC can you make custom sizes? When are you gonna start selling? I WANT ONE!

later

pebbles

Cool good to know. I have never owned a CF board myself (and still don't) :(

I could already do custom sizes but now I can do it a lot easier. Hopefully once I get everything set up I will be able to make boards quicker so it won't take so long for a board. It should also bring my expenses down.

Selling? I dunno. Maybe a few here and there for friends and such ... The last one I made was for Colin who lost his board, and this one is for Josh who broke his. Hate to see a buddy have a $600 bad day.

Just figured with the CNC the next step would be selling boards. If you could make 15-20 boards a year it might be profitable.

Later

pebbles

Yeah I'll have to think about it... Guess it depends on how many people show an interest.

If you sold the boards for 400, complete; had a 2 or even 3 year warranty (does anyone do 2 or more years?); and maybe had some sort of custom graphic, how could people not be interested in your boards?

@#$ I have shards of carbon fiber all over me. I feel like a porcupine was rolling around in my clothes while i was sleeping.

LOL! that would be the reason not to make them ( unless you get a huge fan blowing the stuff all outside )

I'm thinkin this may be a project worth throwing some money at.....