9'1" longboard in sandwich

General Discussion
1

Here is a pic of my first sandwich project.

The yellow on the sides is PU foam.

I started this project a year ago, before I knew that it was (almost) impossible to sandwich surfboards like windsurfboards (because of the thinner rails).

So I started this project like a windsurf sandwich, now the PU foam is plastic surgery for my mistakes.

But I’ll get it surfable!

The fin:

There is still a lot of work on the fin and the fin will fit in a US box.

Now I have a question:

The rails look really terrible

(this is the worst part)

The sandwich looks thik because it’s cut under an angle and it’s 5mm sandwich!

What do I have to do?

Fill the holes left (with ??) or cut/plane of +/-2cm from the rail and glue rails to it?

I feel shamed for this.

But I will succeed!

2

I don’t know about the rails, but my question is: “Where are you going to put the screw in the fin for the box?”

3

:slight_smile:

Yeah, this fin is made of foam. I will glass over it (like wooden fins).

The fin base will be made in a mould the foot under the fin is just to put in the base, a sort of anchor that will make it easier to put the fin on the base.

I hope you understand this. I don’t really know how to explain it.

If there are other remarks on this project, just shoot!

4

OK, Hans, got it.

As for the rails, I still don’t know… I would probably sand the foam and glue wooden rails, maybe…

5

Cut the rails off and add either balsa or pvc rails, should be able to make it look like new!

6

Plane off those rails until you have a flat rail all the way around. Glue on some more of your green foam - enough layers that you can reshape the radius you want. It’ll come out fine. :slight_smile: The layers actually help with rail banding. I’ve made a board like that - light EPS inside, PVC sheet foam outside. Mine came out uncomfortably stiff and quite heavy. Watch that PVC, it can suck in quite a bit of resin (for something which is supposed to be closed cell).

Skins already done, rails in the bag:

Shaping the rails:

7

thanks, that’s what I thougt to do.

I’ll start immediately.

8

Kill 2 birds with same stone:

  1. Cut rails till flat surface

  2. “Glue” 1 or 2 PVC bands to the rails, but using epoxy resinn and a fiberglass band under each PVC sheet, so you’ll have a “double-sandwich rail”. Stiff like hell!!! Then, re-shape rails.

9

I’ll do the rails with XPS because I only find 5mm PVC sheets and I don’t want to glue 4 sheets on the rails.

I found 20mm XPS sheets I think that will do it!

10

The new rails:

And I was stupid again.

I thought I could reuse a vacuumbag ----> noooot!

I’ll need to make huge nose and tailblocks (yes, I’ll put them in angles).

Never start sandwich again. Joke, I’ll start a new one in a year or five.

Next one is back a traditional one.

to be continued

11

took it out of the bag, luckily the tape did a wonderful job!

tomorrow morning CET I continue

good night