Chambered Balsa Questions

I have a nice balsa blank consisting of rocker-cut, glued up beams. I want to chamber it and have access to a large band saw. It would be easier to cut if I sliced it up before shaping it. I would tack it back together, shape it, then break it apart to chamber.

If I do it this way what kind of glue should I use that would hold well enough while shaping but break apart cleanly for chambering?

The other alternative is to shape the blank then rig up a jig of some sort to hold the board while sawing it into three sections.

How do you balsa experts do it?

LeeV,

I have my own way of doing that, but I defer to the resident expert on chambering, MR. JIM PHILLIPS. I’ve seen Jims’ technique, it’s quite elegant. Whatever he suggests to you, DO!

Aloha LeeV

After sawing 3 cuts, you just need a dab of regular Elmers glue in a few places along the length. Maybe only 3 dabs for a short board 4 for a longer one. It would be a good time to add redwood stringers also!

Small dabs only about 1" diameter when squished out. Center them in the thickness so that if they tear a bit of balsa it is not near the surfaces. If it breaks apart shaping just glue again. Better to have too little than too much!

Mahlo Bill! I’ll take photos of the process. I hope Jim fires up the computer…

I am about to chamber my own balsa blank, and was also wondering about the glue tacks. I was afraid to use Titebond, since it seems to bond so well. I have an old bottle of Elmers wood glue. I’ll just use that.

One other question on the same topic: What is your tool of choice for chambering? I was thinking about using a 1’’ forcner drill bit.

I have an old ('71) Surfboard Builder’s Yearbook. A section in the book has Diff chambering a Balsa. He used a router.

I would just use white glue, the wood glue is going to rip the wood too much.

Aloha swied,

Agree with Bill Thrailkill about Jim being the go-to guy on balsa. He was my inspiration and source of info when I began balsa boards. Until he chimes in I’ll just say there are several ways to go about it. It doesn’t show once glued all back together so you can choose a blow and go method or take your time and do it tidy and neat which will be your little secret until a future archiologist cuts it open some day to inspect. I’m of the mind, and I know Jim is, to do it right. Take the time and you’ll have more pride in it. The arguement is that hey, it’s just blowing away sawdust so just get er done the fastest way you can!

Blow and go:

  1. Staggered holes with a flat or spoon bit every six inches or so and use a jig-saw or scroll saw to join the two holes in a long oval chamber.

  2. I’ve seen some guys simply drill gobbs of large holes with a spoon bit every couple of inches down the length of each board.

  3. Just rout away randomly.

Slow and go:

Carefully plan out a pattern of chambers. Use a jig to rout chambers and some like to chamber in on each side of each board to keep a 3/8"(or so) wall between the chambers so the chambers aren’t all the way through the board (leaves an eyebeam down the center of each board). Aalternate or stagger the chambers. If you use the method of shaping first and chambering last (instead of chambering each board then glueing and shaping), you have the advantage of more precise chambering to thinner tollerences. If you vent you’ll want to end up with every chamber joining by at least a small connection hole.

Chambering can take a lot of time to do right, but considering the overall time it takes to make the whole board, especially if you’re milling and making up your own blank with stringers, etc., the chambering is not a huge deal. As Jim will tell you, there is a point of diminishing returns where trying to get the tollerence down to the nats hair just doesn’t yield much total weight in extra balsa sawdust.

Maybe Jim will chime in and give you better advice, but there’s a few wild ideas.

Enjoy the ride!

richard

Quote:

I am about to chamber my own balsa blank, and was also wondering about the glue tacks. I was afraid to use Titebond, since it seems to bond so well. I have an old bottle of Elmers wood glue. I’ll just use that.

One other question on the same topic: What is your tool of choice for chambering? I was thinking about using a 1’’ forcner drill bit.

Aloha Swied

I use a long 1/2" dia. router bit and remove material in steps, routing deeper with each pass. Rails pieces, where the thickness tapers rapidly, you have to stagger the chambers getting smaller inwardly. The length of the chambers and the outer skin thickness is all relative to the risk you are willing to take of possibaly punching your foot through in a bottom turn.

Um, from the rankest amateur, I’ve heard that a hot glue gun will do the job, and has the benefit that you won’t wait overnight for the Elmer’s or Titebond to dry, either. And, if it comes apart, use more next time, or something else.

I guess any wood glue, including foaming poly, will do the job, if used in the right amount. Good idea to put the glue spots “inside” where if they tear a bit, it won’t show.

Hi

I’m a complete amateur - made a balsa 10" old school longboard last year that I chambered using a forstner bit - worked very well - used a range of sizes to acommodate the varying thickness along the blank. This method however only cuts circular holes and therefore does not remove as much materail as you would doing round cornered rectangular setions with a router. However, I found thhat I actually really liked the weight that I was left with as being far heavier than a foam board it gains so much momentum even on small waves and is an incredible ride - I love it. I’ve just chambered out a new blank for a retro fish but only took it out of the 2 mid ‘planks’ - not the rails, again because I don’t want to make it too light. I shaped the longboard from stringerless blank, cut along the stinger lines (tripple stringer on a band saw) chambered then glued back together with resin before giving the board a final skim to clean her up, cut the rails and fine tune.

I can’t wait to get the fish finished ready for spring over here which hopefully may be a little better than the winter’s working out!

Cheers

Richard

Absolutely DON’T chamber first, you have no control over skin thickness while shaping.

I had bought Mar Bravo pre-chambered blanks in the 70’s and cut into the chambers on nearly all of them.

Mar Bravo built a Buzzy Trent blank for Brewer, I had to route out the bottom and re-skin it as Dick had hit nearly all the chamber along one side.

I shaped for Donald Takayama and he gave me a pre-chambered blank that a customer had built, I shaped right through those unknown location pre-chambers

When Rhino was selling the pre-chambered, styro filled blanks, I repaired so many of them that were sold in the San Diego area.

Lay out the plan shape on the blank as you build it, this way you can see where the planks exit and then spot glue back from the lines 4-6". This keeps from snapping off the tips of the rail pieces as you break it apart.

As for the amount of glue, only a pea sized drop at each place, about 2 feet apart, you will be amazed how well it holds and how difficult it can be to get apart. If it prematurely comes apart, add another drop of glue, better to easily be taken apart than having to beat it to death.

Completely shape your board, shy of the sanding stage, when satisfied break it apart.

When re-assembling after chambering, put only 2 or 3 sections together with rocker straight edges to clamp to. It is very hard to keep everything aligned and doing a minimal amount of sections at a time is better than sorry later.

When I finally get to the rail section, I use strips of inner tubes to hold on the rails without scarring the wood, clamps are impossible at this point on curved, soft wood.

I used to chamber all the way through the pieces from one side, but over the years have morphed it to chamber half way from each side and stagger the chambers half way along each other.

I feel there is less of a chance of busting through if you fall on a knee or elboe and with the crown of the deck, the chamber isn’t ultra thin on one edge and thick on the other. ( leave the chamber dividing walls about an inch thick, this is where many chambered boards fail)

The rails as Bill Barnfield mentioned are very difficult to manage, I tried various router bits and shapes, but nothing was satisfying as the rail was even more difficult to hold steady.

I, during the slow times in building boards have had to go back to fine cabinet building to survive the winters.

Cabinet builders have a tool called a post router or over head router.

After using this tool to do inlay patterns on cabinet doors, I realized I could employ my 12 speed drill press to do the same.

With a section of 6" aluminum angle, clamped to the bed of the drill press the distance that you want the chamber skin to be (I generally leave the rail section a bit thicker skinned than the centers 5/8"-3/4")

I set the stops to keep the 4" router bit about 1"-1 1/2" from the surface of the bed, this way the outer edge of the rail always stays the same space away from the bit.

Draft out the chambers, go in and first plunge cut with the router bit and drill press, then come back and slide the rail along the fence and clean it up, but only go in the direction the the router bit will pull the work into the fence, otherwise it will walk away from the fence and cut out throught the side of the rail.

When finished with this phase. move the fence and plunge out the ends of the chambers. I have a bitchin little tool called a scorp, it is a loop knife on the end of an exacto handle, you can go into the bottom of the rail chambers and clean them up so finely with a nice rounded bottom curve.

It taks me an entire day to chamber a long board/gun, if you are in a hurry, don’t attempt.

What do they say? “No one has time to do it right, but time to do it over”

This thread has some great information, and it couldn’t have come at a better time for me. I was considering chambering before shaping because I was afraid of not being able to break the boards apart. After reading the comments from the posts above I am now convinced that I have to do the shaping first.

Right now I have 11 unglued boards. I am currently in the process of gluing the pieces together two at a time. Eventually, I will have five thicker pieces that I will tack together. This is kind of time consuming given my limited number of clamps.

I had previously added dowels keep my boards lined up. The dowels are all located close to the center. I’m thinking that I shouldn’t put any glue tacks near these dowels, since it might make it harder to break apart. You can see them in the picture below.

Hello Bill

Chambering as you are doing in the picture looks to be very wasteful of wood. . . . why not just run some crossways frames where the remaining pieces of internal wood are? Your method uses about twice the wood compared with HWS methods, with no advantage.

Also, if bent planks were used instead of a deck and bottom rocker cut out of straight logs the board will be much stronger as the grain will be following the deck and bottom curve.

I suppose the method suits foam board shapers as they can use their usual shaping methods, that’s about the only reason I can think of for the log chambering system.

Roy

Hi Swied -

Agreed, this thread has some great info.

With total combined balsa chambering input from experts like Bill Barnfield, Richard McCormick, Jim Phillips and additional HWS input from Roy Stewart, I don’t think you could ask for a more complete explanation.

Thanks to you guys for contributing and to LeeV for asking.

Quote:
Hello Bill

Chambering as you are doing in the picture looks to be very wasteful of wood. . . .

Aloha Roy

You are probably right but my goal wasn’t conservation of materials it was light weight with the least amount of time and effort. I hope someone down in Ecuador is planting new balsa trees!!

why not just run some crossways frames where the remaining pieces of internal wood are? Your method uses about twice the wood compared with HWS methods, with no advantage.

Were I a “HWS” builder, I probably would do as you have suggested, but the time considerations are immense for me. The advantage you apparently aren’t counting, is one of time and simplicity. Materials are almost always cheaper then man hours. So if some methodology allows me to go faster at the cost of a bit more material, my techniques will be drawn strongly in that direction.

Also, if bent planks were used instead of a deck and bottom rocker cut out of straight logs the board will be much stronger as the grain will be following the deck and bottom curve.

Actually Roy, most balsa blanks are made with curved pieces of Balsa. Mostly because the pieces come with some degree of arch in them already. Still though it isn’t enough to get the full rocker out of one piece which means extra has to be scabbed onto the deck/nose area usually. But then the lengths of the balsa are often not long enough anyway so some extra has to be added anyway.

Strength while important, is not that big of a factor on most balsa boards as they are pretty darn strong and resistant to breaking anyway. Your observation is valid. Just not necessary.

I suppose the method suits foam board shapers as they can use their usual shaping methods, that’s about the only reason I can think of for the log chambering system.

I think you have that one figured out correctly. I guess we could build our foam boards with foam sheets and cut them into skins and struts to support them… It could probably save a lot of foam but it would vastly complicate the process.

By the way Roy… I have some speed data to share with you from a day at Laniakea. But I am getting way busy again and it will have to wait till I get some freedom to get into that discussion.

Hope all is well with you and your family

Roy

What I didnt mention in the last post was that I had shaped the blank before cutting the chambers- just put it back togehter at the end for a final clean up.

The very second a woodsmans axe or saw starts at felling a tree, wood is being “wasted”.

With the classic style of building balsa baords, what I hear most often by the cutomer is, “I don’t want it to have any scarf marks showing”. This precludes doing it on a frame and spar method, I have done many this way, but have added nose and tail blocks to cover where the top and bottom skins exit at the ends.

In a production world where time and money unfortunately cross paths, using full size planks, is the least expensive method to build BALSA boards anyway.

Conventional contemporary wood board designs have crown along the deck and using a frame and spar is out of the abilty of most builders. This is why the extra wood is suited better for this style of board.

I built 25 of the traditional hollow “kook box” boards for the Gidget Company to use as back drops for a trade show. The first one was the learning curve, I went out and bought some new tools for the project, as doing it the way I was, I could see I would NOT get the job done in my life time.

I built a lay out jig that held all the frames in place, router cut the solid nose and tail pieces, as well as the top and bottom skins.

It was still quite a job to do that many, but still came in under the deadline.

This is why we are all involved in this marvelous unending project we call board building, swimming in with flippers, standing up paddling, being pulled by a kite or PWC, it is still surfing no matter how we slice and dice it

The last time I saw Diff he was absolutely giddy, for Diff, about his new “seceret weapon”. He was using a cheapo small electric chain-saw to chamber the boards. Easy, fast and accurate.

Ace, I shaped Diff’s wood boards for the mainland after he had roughed them and the chambering was anything but clean and neat.

There is a tool called a chain mortiser and I would love to have one to chamber with, but they are big, expensive and I have thought how to attach one to a plunge router base to do what Diff did.

It’s not how fast you do it