I know its been covered here, but I just want to make sure I got the right stuff. (this is a pic of the 2" stuff, but at my store they have the same in 1" thick). Its expanded polystyrene, the plastic sheathing peels right off. I want to bend the rocker in, and glue 3 sheets on top of each other, kinda like squalyboy did with his board. What do I use for glue? Is this stuff shape-able? Thanks for answering my newbie questions!
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http://www2.swaylocks.com/node/1020650
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wow, that was quite a read! Great thread, 'tho, very informative - thanks for the link!
Yes it is the right 1lbish EPS for making a very cheap board. The best use for this stuff is as a core. When I made a 9lb 8’10" balsa skinned longboard with it I glued a 1"sheet on the bottom and a 2" sheet on the top so I wouldn’t have to shape my glue line. I used a very thin layer of Elmers Utimate glue. In hind sight an epoxy-microballoon slury as glue and a stringer would work better.This place has more options http://www.whitecap.com/categories/Polystyrene_Products___Acces . I like to use the high load blue xps for the rails and ends because it shapes better and is water proof.
PS: The only reason for using this stuff is because you like to do things the hard way like me.
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The best use for this stuff is as a core... I used a very thin layer of Elmers Utimate glue. In hind sight an epoxy-microballoon slury as glue and a stringer would work better.This place has more options http://www.whitecap.com/categories/Polystyrene_Products___Acces . PS: The only reason for using this stuff is because you like to do things the hard way like me.
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That is my intent - to use it as a core, and not for the rails. I don't necessarily like doing things the hard way, but I have a natural tendency to make things complicated! =) So the elmer's glue is problematic? I don't have any microballons - or is that just foam shavings? What kind of epoxy? The elmer's sounded easy enough, if its not problematic. I will look at that website.
yes
we’ve been glueing, bending and building blanks with them since 2004
even before we could afford a vacuum setup
a little on the soft side maybe .75lb but that’s what Bert likes per his latest interview
just keep the skins thick (none of that veneer stuff) 1/16" - 3/16"
resawn and thickness sanded homedepot cedar works fine for skins
-oneula/sharkbait
(kings of the homedepot/lowes crappy foam boards)
PS
after awhile you’ll become an expert on peeling off that plastic liner
For gluing foam to foam Elmers Ultimate works great because it expands into the foam. On the down side it cost about the same as epoxy and is not good for impact loads like the top skins take. I think it is fine for making a core.I use Resin Research epoxy and micro balloons are a filler made out of small very light glass balloons.
If you are going for a stringerless wood skinned board it is best to set the rocker when the skins are glued on and not on the foam glue up.
From what I have seen of your cool build style with the solid pre shaped-rockered rails I think you might be able to just shape-foil the foam while it is flat and then bend in the rocker when the skins go on. Your rails would work as a rocker table. Easy peasy!
Well that's good to know - sounds like just exactly what I'm planning.
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For gluing foam to foam Elmers Ultimate works great because it expands into the foam. On the down side it cost about the same as epoxy and is not good for impact loads like the top skins take. I think it is fine for making a core.I use Resin Research epoxy and micro balloons are a filler made out of small very light glass balloons.
If you are going for a stringerless wood skinned board it is best to set the rocker when the skins are glued on and not on the foam glue up.
From what I have seen of your cool build style with the solid pre shaped-rockered rails I think you might be able to just shape-foil the foam while it is flat and then bend in the rocker when the skins go on. Your rails would work as a rocker table. Easy peasy!
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Great info, and an intriguing idea there on the pre-shape! But problem is, don't you have to bend the rocker in as you glue the panels together? I mean, you couldn't glue the panels together, then shape the rails, then bend the blank - could you? You are kind of reading my mind on the planned build, 'tho! I'm kinda thinking add the foam at this point, shape it, then add my deck skin over it:
On my compsand builds I add the rails after the bottom skin is on the foam then shape the rails and add the top skin. I have changed the rocker on boards with wood rails & bottom skins already on when I put the top skin on with a rocker table and bag.
With your style build I would just get a thicker sheet of foam or glue some up,shape in bottom contures, and add it when you put the bottom skin on. Then shape the top and add the top skins. If your skins are 1/8th bender ply or thinner veneer they will hold the foam contures pretty easy. You may need to graduate to a $30 vacuum bagging set up like me. I am a flooring conman so I built this out of spare junk.
Good night,
[img_assist|nid=1030197|title=vacuum set up|desc=|link=none|align=left|width=406|height=640]
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But problem is, don't you have to bend the rocker in as you glue the panels together? [/quote]
What up huck. That's usually best but not necessary with flexible ultralight eps cores.
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I mean, you couldn't glue the panels together, then shape the rails, then bend the blank - could you? [/quote]
A post shaped eps core will bend much easier than the raw unshaped core, especially in the nose/entry area.
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I'm kinda thinking add the foam at this point, shape it, then add my deck skin over it:
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That works. If it doesn't, you will likely learn a lot of things (to avoid next time) along the way.
You will need to vent your end result.
there’s many ways to skin this cat
but what we did is shape the bottom contours into to the bottom flat sheet on a flat table for support then bend in the rocker using a form that has the curve you wish to achieve.
at the same time we’re gluing the multiple sheets of cheap foam up somethings using internal springers of wood or glass and applying the bottom laminate at the same time over the preshaped bottom in a vacuum bag or suing palstic stretch wrap tape.
pop it out, clean up the out line and apply the rail bands or shape the deck
to make things easy these day I secure the rocker using a thin single band of wood like ply or 1/8"-1/4" balsa followed by a 1" thick strip of XPS or Precision Board which is the cheap man’s corecel. some special non foam eating water based contact cement and its a pretty simple process.
if you use elmers and have a rough shaped initial full rail band let say out of bending marine ply or 1/16 sheet poplar or maple or even just a masonite template. You can apply your rail band with screws and the cut your deck profile in a single slice of a hot wire bow. this will save you alot of time in turning the deck down. Kind of like hotwiring blank hacker style without a block.
you can finish shaping the deck down once the bottom is glued on but the blank will be more stabilized for shaping on racks once one rail band gets put on with the bottom even if its just a couple layers.
as mentioned you can re-rocker any of these blanks prioir to applying the solid rails.
If you build the rail frame first, you can just insert outlined sheets of foam core and secure them and the bottom to the rail frame in a single bagging then finish shaping the deck and rails before applying the deck skin which almost sounds like a Danny Hess method.
best of luck…
gave up on wood hollows though?
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gave up on wood hollows though?
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I don't think so. Always trying something different. Just along for the journey, never sure where it'll take me! =)
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You may need to graduate to a $30 vacuum bagging set up like me. I am a flooring conman so I built this out of spare junk.
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That looks good! I haven't a clue about vacuum bagging, 'tho I imagine I'll get there someday!
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...That works. If it doesn't, you will likely learn a lot of things (to avoid next time) along the way.
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LOL, excellent point!
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You will need to vent your end result.
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BTW, when I do that my wife always leaves the room hahaha!