build eps/xps with hempPET and bamboo skin 6'2

General Discussion
1

Started getting my summer boards ready

doing a 6’0 pu with hempPET and 100% bamboo woven skin

 

As well as the one below

 

Always been playing with either EPS and Xps love the performance difference between the 2 cores

so why not try the both together

[img_assist|nid=1068530|title=eps xps mix|desc=|link=none|align=left|width=485|height=234]

 

 

 

 

 

 

 

 

 

4 layers starting from deck

1x 10mm layer of RTMX xps

1 x 25mm layer of H grade eps

1 x 20 mm layer of RTMX xps

bottom layer of 1x 20mm of eps

 

Why? why not? good thing about it is most of the xps is on the rails so stronger impact strength and fin boxes mostly will sit in Xps so less re-enforcement needed around the boxes.

deck will have a layer of Hemp PET so not too worried about the EPS crushing…

 

 

2

finished the boards, dried and sanded with 600 wet and dry

 

ready to ride

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3

ok sanded up and ready for the final spray… found this spray putty it fast drying and gives great coverage, amazing stuff!! Waterproof and cost is $8 at supercheap auto here in oz.

Only issue is that it comes in Grey… or Grey… (lucky I like this colour!)

 

Dries in 30 mins ready to sand… hopefully surf this arvo!

 

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4

Make sure with the hemp PET that you use a resin with good elongation otherwise you get starring and cracks in the deck. 

5

Thanks greg

Must be using the right resins, as no issues in the ones i have done so far.

 

ok hemp PET deck strip is on. will clean up the edges but when filled and painted you wont see the skin layers

[img_assist|nid=1068721|title=hemp PET deck patch|desc=|link=none|align=left|width=320|height=191]

 

 

 

 

 

 

 

Next is cutting out the 100% woven bamboo cloth and stretching to cover the deck.

[img_assist|nid=1068722|title=all the layers…|desc=|link=none|align=left|width=323|height=146]

 

6

Hey interesting build!

Like the layered look of all the bits and will be interested to hear how it holds up etc… got some bigger pics?

7

stretched out and laminated to the deck, love this stuff can use your hands to push out bubbles in the lap and sanding is so much better in boardies!

[img_assist|nid=1068802|title=bamboo laminated over hemp PET on deck|desc=|link=none|align=left|width=539|height=219]

 

 

 

 

 

 

 

 

 

 

8

Thanks nocean.

Since they Sways changed how you upload pics,  all my pics come out small… (I am doing the same build on Sanded and pics on there you can enlarge)

Built a few like this and  they hold up well, the glue I use is handles heat well and is quite easy to sand, though this is the first time I have used eps and XPS at the same time. usually its different desities of the same foam.

 

Bamboo layer pinned on the bottom ready for laminating.

[img_assist|nid=1068936|title=bamboo pinned on the bottom to be laminated|desc=sanded.com.au|link=none|align=left|width=699|height=527]

 

 

9

Love build threads, especially using new ways of dealing with the core.

  1. What glue are you using to stick the layers together? (I've been pointed to Illbruck PU010 after fails with shaping hot glue, PVA and epoxy)
  2. Are you glueing up the core on a rocker table?
  3. Lastly, how do you hold the core layers while glue sets?
Thanks for sharing your build and ideas.

Red

10

Hey Red

The glue I use is Selleys Aquadhere Durabond - heres the product description

“Durabond is moisture curing, high strength, polyurethane construction
adhesive. It has high strength and water resistance making it excellent
for jobs requiring extra durability, both interior and exterior.Durabond
is sandable, paintable and stainable. It is suitable for bonding wood
to almost anything. A superior adhesive, it is also excellent for
bonding materials other than wood.”

I do use a rocker table but its set up for the deck line. following the deck rocker put less stress on the blank so glue has a better bond with less stress.

The way I set it is a layer of ply on top with planks of wood about 300mm apart then clamped down.

I will post a pic when I get a chance

 

11

So I finally have a chance to put a pic of the rocker table I use.

Its a deck profile table, when bending and glueing xps its heaps better to use the deck curve instead of bottom

keeps more flex in the blank and less chance of the blank having a stress snap.

 

 

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12

ok, been away for a bit but back on it now…

fin boxes are in… next step, filler coat ready for sanding, i know I
will get comments saying why the filler coat?

Bamboo you lightly sand
and then put a filler coat on. it makes it stronger and less chance of
the deck “starring”.

I use a lightweight filler that is used in fairing
racing 18ft skiff sailing boats, its about 1/2 the weight of q-cells.

 

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