Well after a complete failure trying to build a HWS, I decided to jump into the realm of foam. The shape was made off the Steve Lis template and drawn up on a CAD program I have. Blank is made from to sheets of 1.5" Sheltersheath EPS from Lowes. Not the greatest stuff, but it will work. I plan on using 3 layers 6 oz cloth top and bottom.
I learned there is an easy way and a hard way on fin making. The hard way is to sit there off and on for 8 hours with a Sureform and sandpaper in 90+ degree heat. The easy way is buying a Black and decker cyclone 4 in 1 sander and finish in about 45 minutes in an air conditioned garage. The template is the steve brom template that chipfish posted.
I sealed the board with spackle and it just needs a final sanding and it will be ready for glass. I plan on using some west marine epoxy since the store is nearby.
I want to thank everyone on this forum for the inspiration in one form or another (too many names to mention) and especially the person who came up with this site. Tons of resources and people willing to help each other out.
I basically cut the foam sheet in half. Glued it together then cut in half again and glued the stringer in. Used a belt sander with a 60 grit belt like a planer to cut the rocker. I originally started with a surform. Very time consuming. I will definitely go the hotwire route the next time.
Was the 1.5 EPS all you could get at Lowes? I’m trying to get 6" x 12" x 8’ EPS billets here in New England with little success. Unless I want to spend $250 plus and get a pile of the stuff. I’m just a one-off guy, though. Any hints for a source?
Been awhile since I have posted any progress. My order from fiberglass supply showed up the other day. I glassed the first bottom layer yesterday and just finished the first deck layer a few minutes ago. I wish I had access to that glassing video. I am kinda learning as I go along. It’s easy to read about the process versus having to actually do it. My laps suck, but it’s my first. The excess strings are enough to drive you crazy. Learning another lesson about glassing, LET SOMEONE ELSE DO IT. I am using RR epoxy and it is very user friendly.
Shaping seems to be the easy part. Guess I should have hung out downstairs in the glassing room instead of upstairs in the shaping room at Seasoned surfboards during highschool.
