9 foot, 2 piece Travel Board.

General Discussion
1

 

Got a snapped PU/PE longboard in for me to repair but the guy lost the front 2 foot piece.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P210.jpg[/IMG]

Delam on the bottom.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P209.jpg[/IMG]

2 ft missing off the front.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P211.jpg[/IMG]

I quoted $100 so he abandoned it. Its a lovely board to hold, no dings, but also no nose.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P206.jpg[/IMG]

 I carted it home across the back seat of my car, so I figure if I could make an add-on nose it'd be a 9 foot board that'd fit in the back seat. Easier than putting it on top or laying down in the passenger seat.

 I squared off the front edge.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P212.jpg[/IMG]

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P213.jpg[/IMG]

 Glassed down the delam.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P214.jpg[/IMG]

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P215.jpg[/IMG]

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P204.jpg[/IMG]

And then I figured out that a scarf joint would give a bigger contact area between the 2 parts. The overlapping pieces would also be stronger than a butt joint. ~imho~

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P202.jpg[/IMG]

The front edge is squared off with about a 1/2 in step so that the front piece has a solid wall to sit against. It should give a really obvious 'registration' or solid feel to the join.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P201.jpg[/IMG]

To connect the two pieces Im going with 4 thru hull screws, they will be the expendable 'weak link' so that if the board gets a pounding then the screws will fail rather than ruining any glasswork.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/P207.jpg[/IMG]

 The twist in the build is that the front piece will be EPS and epoxy.

2

This is great project idea. Recycle into something really useful. 

I’m really interested in building a two part board for a trip to mexico in Feb. There should only be small waves there in the winter.

The airlines are not taking big items done. One of those situations were items have to be 60" or less in length, including the boardbag. Two piece, or a 4-10 Simmons that may not have enough for my 180.

Your joint and connecting hardware sound real interesting.

3

How in the world did you cut that scarf joint?

Very resourceful, BTW.  Keep us up to date your project. 

 

all the best

4

For the scarf joint I put the board at an angle on the racks, surformed and sanding the area as horizontal / flat as I could

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/SURFFOILS%202010/9ft2in004.jpg[/IMG]

 and then glassed and hotcoated several times. The hot coats  levelled themselves so that its perfectly flat.

Well, as flat as resin wants to be.

 [IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/SURFFOILS%202010/9ft2in002-1.jpg[/IMG]

 Getting the nose section to fit is a bit of trial and error but its coming together ( ha !) nicely.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/SURFFOILS%202010/9ft2in009.jpg[/IMG]

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/SURFFOILS%202010/9ft2in008.jpg[/IMG]

The whole nose section has 7 thin carbon stringers placed in shallow grooves to stiffen it up.

[IMG]http://i153.photobucket.com/albums/s225/SURFFOILS/SURFFOILS%202010/9ft2in012a.jpg[/IMG]

 I'll get the 2 parts to fit, then shape the nose and glass it.

 I think its possible to make different screw-on noses with different contours so you could have a concaved or veed one or very thick or thin nose so you could swap noses to suit the waves or rider. 

5

genius!..nice..work....