3D printing large surfboard fins

I decided to use translucent filament for the first print of the next version of the edge protectors. I think they look nice, particularly the ‘Gyroid’ infill.

It also let’s you see how the inner workings are arranged.

I still have not included the piece of nail file, but I think I found where I can squeeze it in.

Now the edge protectors contain 2 spares of every part required to fit the fin to most boxes.

The spare grub screws ( to set the depth of the fin in the box) hold in the spare screw plates. 

The cable tie range of move ment has been restricted further to ensure that it secures the longer Allen key.

 


The fin for Hans is finally ready and on it’s way to Europe! 

The packaging is designed to make any padding for shipping unnecessary. And all the parts are for continuing use.

Photos show:

Fully wrapped for shipping 

Cable-tie slid up and leading edge cover removed

Pulled out surf-key (for use in the surf with a lanyard)

Using the surf-key to eject the other Allen key. It also ejects and unscrews all the other spare parts in the cover.

The surf key is the only part that needs to be removed, the rest are spares that can stay in the leading edge cover until needed. 2 set screws, 2 plate screws, 2 plates and the 2 keys.

 

 





It’s great to see the extra attention to detail you’ve put into the packaging. Seriously impressed!

Where do we sign up? :smiley:

 

Seeing that Australia Post envelope in the mail box, reminds me of being a stoked frothing kid on Christmas morning, but the true joy begins when paddling into a wave with one of these fins installed.

The latest edge protectors with extra screws and break away screw plates are indeed an impressive design.

I have an exact version of the fin on its way to Hans, regarding thickness and flex, filament and color, but i have wetsanded mine smooth to 400 grit.  It has a brighter spark than the others.  On some waves, when grabbing the rail and torquing/leveraging both fin and rail to get going quickly on a stretched out wall, they combine to make it feel like one just stepped onto one of those moving sidewalks at the airport. If this happens when not grabbing rail I get stuck on just my back foot or fall off the tail. This partiular fin is very lively and predictable and confidence inspiring, a slight degree more so than the other G-whale fins.

Also on the last wave in, proned out in the white water, and angling as hard as possible up or down the beach, no fin ever,  has allowed the steep angles parallelish to shore that I am achieving, nor the speeds I can achieve with this Gwhale fin.  More than once I found myself back on open face, never having expected to catch back up with it.

All the fin base strength issues, seem to have been sorted out.  I’ve been instructed to try and break them surfing, turning as hard as I can.  Kicking the board out  backside up and over, has been the fin breaker in the past, and the new base designs are not breaking when doing this. Even some more recent version which are not as strong as the latest have not broken. 

I’ve not really driven them into sand very hard as I can’t intentionally destroy anything that is so joyful, and I do fear wrecking my finbox, but my 25LB leashless board has  hit sand and cobbles on the beach loading the fin fore, aft, and laterally and rotationally without issue so far.  

Getting the fin base tabs, both leading and trailing edges, to sit flush with the hull and also resting on the base of the box, is now easy to accomplish on any board, Something which cannot be said for the single tab on fins with roll pins as each board is slightly different when finbox is sanded to the level of the hull. One could also slightly alter the aspect ratio a degree or 3, if they wanted to, and were not much concerned whether the tabs are flush with the hull.

Fins with thick flanged bases, the flanges can now reside directly on the hull adding lateral strength to the fin base, and also add resistance to lateral flex at the base which I feel is great for quick responsiveness to input. The thicker fins feel more solid during hard turns, but are noticeably slower on open face in trim, but still way faster than my regular Dol-fin.  I’ve only one session on the latest fin sent that has a flanged base and tapers to the same thickness at the tip, in weak small conditions, and it did turn quite well, but no opportunities to compare that trim speed to fins without flanged bases.

 

My 16 year old longboard’s fin box is so worn and stretched out from fitting fins previous to the latest dual tab versions,  that dang roll pin requiring sliding, that I have to thicken the base of all fins I use in this board, with epoxy, so they do not wobble obscenely in the box. My finbox is heavily reinforced, and capped, so I’d rather not have to route it out to install new, but I do spend a lot of effort thickening each fin sent, and then sanding them to fit tightly.

This means that fins I have tested,  are too thick to insert into almost any other fin box without sanding the sides back thinner, and it is amazingly difficult to sand fin bases evenly thinner without tapering them, which induces base wobble and lack of instant response to input.

So I have only gotten one G-whale fin into another’s hand at this point, and pretty much want to fit the fins to others boards myself, rather than allowing others to do the base thinning fine tuning.

This G-whale fin now in the hands of another, is one which was too flexible for me, which I suspected before riding it, and whose unmodified  base I shimmed with construction paper and wetsand paper, instead of thickening it with epoxy, which is superior but much more labor intensive, in terms of efficacy in reducing base wobble.  This person had been handed the tri color Harftub 9.5 shown in the first pic on page one in this thread some 7 months earlier.  I heard through the grapevine he was raving about its speed and control on a HPLB with side bites, but apparently it broke and he was trying to fix it as he liked it so much when I saw him again, and handed him a 7 7/8" deep version of the ~9 5/8" deep fin he broke, and the super flexy Gwhale with the new screw plates, metric screws and allen key to drive them.

 

Performance wise, If the Harftub 9.5 earned a 6 out of 10 in my longboard, then the Harftub 7s was closer to a 7 / 7.5, and all the stiffer G-Whale versions are a 9.0+, and my regular raked fin is a 4.5, in my opinion.

The lower aspect ratio deaweeder fin earns a solid 5.5 to 6.5, and feels much more like a regular dol-fin in a straight line and through turns, but is nowhere near as quick and responsive as the Higher aspect Harftub and Gwhale fins, but is noticeably faster and looser than my traditional Dolfin. 

Trying these lower aspect ratio fins in this board after riding so much High aspect ratio fins, made it obvious the self centering, added stablilty, and added drag of lower aspect ratio, and rarely did I find any of those attributes desirable in this board. I was being caught behind on waves I expected to be able to stay on open face, feeling the extra drag, and pushing hard during turns, the board was not coming back around under me as I was used to. I  was having to alter my line and not push nearly as hard to keep the fin from stalling and falling in turns, and I much prefer to push hard.

The Gwhale fins whose bases I broke, have been cut down to shortboard multi-fin size, and works amazingly well as a center fin in my shortboard.  They need to be 3/16" or more further back than the trailing edge of regular thruster fins and in that position are very drivey and still loose and quick, but can catch the leash going from sitting to paddling, and not let go, so one has to take more care with the leash over the shoulder when sitting and prevent it from wrapping around a turbucle.

  I am going to borrow a board with Futures fins and modify another GW fin to tightly fit that system’s center box, and perhaps FCS2 at a later date as I want a dedicated HPSB rider to try one. I use Probox myself.

 

 

Thanks Mik, looking forward to test your fin!

Some more instructions…

I’m certain they are not neccessary for Hans, but I’m working on instructions that would be helpful for most potential users of these fins and might as well test-run it here.

The base protector is held on with the screws that will be used to secure the fin in the fin box. I do not screw the base protector back on unless I want to send a fin in the mail. And that is more to protect other mail items from damage than the fin itself. The screws and the set-screws could poke out of the mailing bag if they were not protected.

The aft screw through the base protector also secures the trailing edge protector, in addition to the cable-tie. 

Once the 2 screws in the base are undone, the trailing edge cover comes off.

The last photo shows the full set of included parts. There is of course no need to remove the spare parts from the leading edge cover until something has been lost or damaged.



The UTFB (Universal Tough Fin Base) has come a long way.

Be warned: The fin is made from plastic which will soften and warp if the fin gets too hot. Do not leave it in a hot car or anywhere else that can get over 60C hot! 

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How to adjust the grub screws to a particular fin box / board:

The fins get inserted straight up and down, no pivoting like with  roll pin.

The 2 grub screws in the base are used to adjust the fin’s depth in the fin box.

To adjust the grub screws for your board, insert the fin into the board without plates and screws, at about the position where you want it to be installed. If in doubt, put it further back than you think.

For flanged fins, adjust the grub screws until the flange is only just touching the surfce of the fin box and is parallel with it. You want the pressure on the grub screws and on the other 2 screws, but not on the flange. **Be careful not to damage the flange by pivoting the fin in or out of the box - old habits die hard! **Straight up and down with just a little wiggle…

For fins without a flange, look at the fin in the box carefully and then take it back out and adjust the 2 set screws gradually until both fore and aft screw plate extensions are flush with your fin box. Tilting the fin foreward and backward in the box allows you to feel when both grub screws are contacting the bottom of the box. 

The second photo shows the process without a fin box obscuring the view. Both set screws touch the table, like they would touch the base of the fin box. That put’s the fin at the correct angle for the particular box.

Either of the 2 keys can be used for this adjustment process. The adjustment may need to be repeated for use in another board, or if you want to move the fin fore or aft by a large distance in the same box. But basically it’s a once only process if you use it in the same board.

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How to secure the fin in the board after adjusting the set screws:

The last photo shows the screw plates. They make inserting the screws a breeze, but need to be inserted into the box in the correct orientation. The side with the nut goes toward the board, the side with the funnel goes toward the fin. If you install the plates the wrong way around, then the nut will pull out of the plastic part too easily.

Put one of the keys through the funnelled side of the screwplate and slide it into the box. Repeat for the second plate. Then push the fin straight down into the box. The screws will find the nuts very easily due to the funnel shape.

Do not tighten the screws too much! Once the screw extensions are bending into the box ever so slightly, it’s enough. Give the fin a little whack fore and aft to test if it is firm enough. It is best if yoiu can get the fin to move fore or aft by whacking it firmly. If you cannot move it without tool, then it’s too firm. The advantage of this is that any impact will be dampened and damage to fin and board (and bodies) is less likely. And you can adjust the fin position in the surf even without the tool!

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How to adjust the fin position in the surf:

This system allows very easy fin position adjustment in the surf. There is no need to completely undo anything to move the fin. If the screws are adjusted optimally, then yu need no tool at all, see above. If you want a tighter fit, then use the key that has the plastic head with a tether through the hole so you do not lose it. String around middle finger will prevent losing the key. Loosen both screws just a little bit. Do not remove the screws, about a 3/4 turn is probably enough. The fin can then be pushed fore or aft. Then tighten the screws again until you can only just move the fin without the tool, or until the screw plate extensions bend a little bit. Again, do not over-tighten the screws.

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Enjoy your surf!

 




I decided to share the STL file for the G-Whale-7-FRR, including the latest UTFB with all the bells and whistles. 

You can slice it to see the inside workings. 

Use carbon bars to fill fin and base to add strength to the PLA shell. 

You need 4x6mm and 1x6mm carbon bars. Stick in until full, cut off under water so you don’t inhale dust. 

It is also possible to use only 1mmx6mm bars.

http://carbonfiber.com.au/prod82.htm  

The carbon bars must be glued or epoxied into the PLA shell, otherwise the fin is substantially weakened and might eventually snap.

BItcoin address is on the UTFB. Not sure if it will be legible enough after 3D printing, but it is decipherable on Slic3r software if you feel the urge to contribute to further tinkering by yours truly. 

Enjoy! 

If you want to print one, look for the filament specs and settings in a later post below! I have produced a lot of PLA rubbish, no need for you to repeat the learning curve.

The attached file holds all the secrets for anyone who is willing to learn the very basics of http://www.openscad.org/. 

The attached file is a .zip file, you need to rename it before extracting. 

You need to rename the file to .STL so that it works.

Another big THANK YOU to Hans for programming https://finfoil.io

 

 

https://swaylocks7stage.s3.us-east-2.amazonaws.com/s3fs-public/G-Whale-7-FRR-OpenSource_2019-10-01(remove.txt).zip__0.txt

Deleted after amending the above post.

Here is how the insides work: 

Use carbon bars, not tubes. Much larger fill volume that way, and enough space to have a 1mmx6mm bar lengthwise on each side to strengthen the tabs.

This UTFB can of course be used for all sorts of other fins. You just need to adjust the length of the vertical carbon bars into the fin, and possibly the thickness.

Tuning the fin works by using 1mm x 6mm bars instead of 4mm x 6mm bars for the thickest shafts. 

You can do the whole thing with 1mmx4mm bars and they can be re-used.

Will be interesting to see if this open source business model will work. Grin!

Bitcoin address for contributions to ongoing tinkering with whatever catches my interest next:

37TTetyGuCFvaGd9LJ26dZC7oeBvQwgV4J



So what material did you settle on for printing? Is it still in PLA?

You can use Polymax PLA for the entire fin. Although, I’m not sure if I have actually tried that.

https://polymaker.com/product/polymax-pla/

 

The colour banding of the fins shown earlier is very intentional. The trailing edge and the screw plate projections must be maximally strong. The middle part, where the carbon bars are, can be printed using a cheaper filament. The first few layers build the sacrificial support system and can be printed from some cheap PLA.

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The last colour change at the fore end of the UTFB is not really required, but you need to change filament to cheap before printing the next fin, anyway. And closing the carbon bar shafts fore and at the base with a hand-held 3D print pen will then require the cheap filament in the pen, no changes required.

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Below are the manual editing levels required to program the filament changes into the .gcode file

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Filament changes x 4 for 0.20mm layers:

Filament 1: esun PLA+ 

Filament 2: Polymax PLA

z0 to z 7.0 Filament 1 esun PLA+ for base - makes support system and coloured screw plate end without weakening anything and minimises expensive filament use

z7.0 to z 47.0: Filament 2 Polymax PLA - makes structurally important part of screw plate end and the trailing edge from the best available material

z47.0 to z105.0: Filament 1 esun PLA+ - the entire part with vertical carbon bars

z105.0 to z140.0 Filament 2 Polymax PLA - fore screw plate projection between set screw and first carbon bar

z140 to finish Filament 1 esun PLA+ - tip of fore screw plate extension.

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Printer settings will have to wait a little, I’m flat out like a lizard drinking at the moment.

Here is a file tha can be used to make the fin by subtractive methods, like CNC milling. 

The support system and the hollow shafts are removed.

Let me know if anything eeds to be changed to make it easier to use.

https://swaylocks7stage.s3.us-east-2.amazonaws.com/s3fs-public/G-Whale-7-FLT_OS_2019-10-05_noSupport_renametoSTL.doc

Here is an STL file of the Universal Tough Fin Base (UTFB) by itself.

No carbon bar shafts in this one.

Plonk your own fin creation on it and enjoy!

https://swaylocks7stage.s3.us-east-2.amazonaws.com/s3fs-public/G-Whale-7-FLT_OS_2019-10-06_renametoSTL.doc

Another snapped fin, another lesson learned: The carbon bars must be glued or epoxied into the fin, or fin strength will suffer greatly. No fins with bonded bars have snapped yet.

The previous files were named incorrectly. I have renamed and compressed them. I would appreciate if someone could try them out and let me know if there are any issues with them.


https://swaylocks7stage.s3.us-east-2.amazonaws.com/s3fs-public/G-Whale-7-FRR_OpenSource_2019-10-05_noSupport(remove.txt).zip_.txt

https://swaylocks7stage.s3.us-east-2.amazonaws.com/s3fs-public/G-Whale-7-FRR-OpenSource_2019-10-01(remove.txt).zip_.txt

https://swaylocks7stage.s3.us-east-2.amazonaws.com/s3fs-public/UTFB_OpenSource_20191006%20(remove.txt).zip_.txt

Readers should note that this fin snapped after many sessions of trying to break it when turning, short of intentionally driving it into sand/reef. 

It snapped kicking out of a wave on my forehand. I had noticed a crack many sessions previously in front of the first turbucle at the base. With horozontal carbon bars supporting the tabs It was obviously not in danger of breaking out of the board, so I left it in place. The session before it snapped I noticed that the flange was no longer resting super tightly on the hull, like when I first fitted it to my stretched fin box. It should have been obvious to me that it was fatigued but I was also told to try and break them.

I believe the flange added some leverage which stretched/fatigued the PLA just below it, until it let go. I feel the flange stretched/ stressed/fatigued the PLA base in a narrower spot than a flangeless fin would.  Bonding the bars inside the fin and to each other, will add considerable strength to the fin. I doubt the amount of pulltruded carbon bars inside this fin could be pursuaded to break at the junction under normal surfing loads, I suspect with the pulltruded carbon bars epoxied in place in the fin would break the finbox/board first. Time will tell.

  One can see the cloth on the sides of the base of the fin, that which resides inside the fin box that I added to get a super tight fit in my worn/ stretched finbox.  I do this to all fins I received adn try, which makes it difficult to hand off for others to try, as the bases then need to be sanded thinner to fit their boards.

The cloth on the sides of the base that I added,  might also have concentrated loads just below the flange

 

I did not lose any of the carbon bars. I felt and heard the fin break and quickly ended the turn and jumped off the board.  The fin slid about 4 inches from the hull of the board riding up the carbon bars, I reseated it, flipped the board over fin first, took the next line of whitewater in, and got out.

I really liked this fin. It was one of the best of these gullwhale fins top 4 easily.  I’ll probably stick it back together someday, epoxying the carbon bars inside.  I will be extracting the bars from any fin in which they are not bonded, and epoxying them rather than polyurethane glue, which I am biased against.

 

These bars were loose in the fin so I could add or subtract bars to dial in a lateral and rotational flex I liked.  I never got around to doing that with the same fin.  The absolute stiffest GWfin was not my favorite, and too flexy was my least favorite fin by a huge margin, but I could see how someone lighter would enjoy how that super flexy fin would load and unload.

  My personal happy middleground in terms of finflex, has yet to be fin(e) tuned.

 

When this fin was newly fit, it had the best fit in my finbox yet, with No wobble at all at the base, helped by the flange resting on the hull. I’m pretty adamant about this tight fit at the box before attempting to form an opinion of a fin.

Hans found a very interesting page about Tubercled Wing Design.

It explains a lot about why the G-Whale fins act like they do.

http://blog.gridpro.com/a-whale-of-an-idea-in-wing-design/

 

The screw-plates are required to use the UTFB.

They can also be used with other fins, they have many advantages over standard screw and plate systems.

I use a 3D-print-pen to lock the nut in place after press-fitting it into the PLA. Some sort of glue should also work. 

The position of a UTFB-equipped fin with these plates can be easily adjusted in the water. No need to fully undo the screws, just losen them a little, the fin can the be moved fore or aft without risking losing the parts. 

The STL file is attached. Print using PLA with 100% infill.

Stainless steel hardware required for each UTFB:

M3 x 20 button head socket x 2

M3 hex nut x2

M4 x 10 grub screw x2

https://swaylocks7stage.s3.us-east-2.amazonaws.com/s3fs-public/Screw-Plate-OpenSource-20190512B.zip_remove.doc

Here are the printer setting for Prusa I3 :

See attached screenshots for Slic3r settings.

The solid infill is required at this 5.5 deg angle to allow diagonal placing on the print bed. If printing at a different angle on a larger print bed, the infill angle needs to be adjusted.

A lot of the settings are essential for success. Check them carefully to avoid numerous mis-prints.

The printer needs to be open (not in enclusure) if you want to do filament changes as described earlier. Otherwise layer shifts will be caused by temperature drop when the enclosure is being opened.

If using Polymax PLA single colour, then use enclosure.

Print temperature is basically higher than recommended to achieve optimal inter-layer adhesion.