Let me say to any of you that have ever harbored the thought of TRYING to pour your own foam, think of the worst surfboard building disaster you've had and multiply by a hundred. Do you remember Bopal India, site of a Union Carbide plant, where thousands of people were killed when an accidental cyanide release occured. They were producing a chemical at the plant that is called TDI, a crucial chemical in Polyuerethane foaming resins. When it reacts, it gasses cyanide, foam as it expands, exerts hundreds of pounds of pressure. The molds are solid concrete, reiforced with steel and outfitted with hydralic clamps to keep them shut during the actual "blowing" of the blank. Mold release paper has to be used to keep the foam from marrying the mold. And least of all, the foam must be poured without being filled with more holes than foam. Why do you think there are only 2 polyuerethane foam surfboard blank builders in the US. They are professionals and we still get blanks that have problems,ah, go ahead, give it a try. Whatta' ya' got to lose.
I would like to see the PU foam board builders shift their production plants to China, it’ll cut the cost by 50% or more. Hope that the retail price of it will cut down to 50% off~~~~~… P.S. 50% off + originally products. Regards, Crabie
Let me say to any of you that have ever harbored the thought of TRYING to > pour your own foam, think of the worst surfboard building disaster you’ve > had and multiply by a hundred.>>> Do you remember Bopal India, site of a Union Carbide plant, where > thousands of people were killed when an accidental cyanide release > occured. They were producing a chemical at the plant that is called TDI, a > crucial chemical in Polyuerethane foaming resins. When it reacts, it > gasses cyanide, foam as it expands, exerts hundreds of pounds of pressure. > The molds are solid concrete, reiforced with steel and outfitted with > hydralic clamps to keep them shut during the actual “blowing” of > the blank. Mold release paper has to be used to keep the foam from > marrying the mold. And least of all, the foam must be poured without being > filled with more holes than foam.>>> Why do you think there are only 2 polyuerethane foam surfboard blank > builders in the US. They are professionals and we still get blanks that > have problems,ah, go ahead, give it a try. Whatta’ ya’ got to lose. Just using Great Stuff(exanding foam in a spray can for insulating) is a pain in the ass.
Did you see, or have seen that Bruce Brown Movie (I think it was Surf Crazy, or Water Logged, or Hollow days) when Del Cannon breaks into the Walker factory looking for a blank. When none were there he tries mixing his own. That setup was crazy, counter weights and hand clamps. It is a wonder how they got any decent foam to work with back then. I guess when it is your setup you get it wired. Even though it was a bit corny it was a very cool look back.
Did you see, or have seen that Bruce Brown Movie (I think it was Surf > Crazy, or Water Logged, or Hollow days) when Del Cannon breaks into the > Walker factory looking for a blank. When none were there he tries mixing > his own. That setup was crazy, counter weights and hand clamps. It is a > wonder how they got any decent foam to work with back then. I guess when > it is your setup you get it wired. Even though it was a bit corny it was a > very cool look back. Hi guy I pour about 80 blanks a day in concrete moulds, Mix all the chemcials every two weeks if i can do it anyone can. I also make the moulds. Its not that hard but it has taken year of failures to get the moulds and foam correct. http://www.southcoastfoam.com.au
about shipping and currency conversion for your fin sets. I know it is not a big order, but I would like to try them out. I don’t want to seem sketchy on the process, but how is it handled with some of your overseas clients? I would like to try some of that hard foam you have as well, but I don’t know what shipping would be like. It would be hard to justify if it was a lot of $. I am close to the clark hub in FL.
Hi guy I pour about 80 blanks a day in concrete moulds, Mix all the > chemcials every two weeks if i can do it anyone can. I also make the > moulds. Its not that hard but it has taken year of failures to get the > moulds and foam correct. As Rabbit says it has taken a year to get it right and that was on a commercial venture, knowing the dangers and problems first. Commercial surfboard foam has been pre engineered with light stabilizers and other secret tweaks, not just a mix and pour insulation/boat foam. Building the molds is an art in its self
Rabbit, I dont have much experience in moulding, pls. correct me if I m wrong: 1) Use a board you gonna make copies, it must be no ding, no dent, no damage, seal all the plugs. 2) Divide the board into two section, e.g. left & right 3) Spread even the release wax or agents to left section if you plan to mould it first 4) Flip the board horizontally, using resin + fiberglass to lay on the section, wrap the entire section, normally 6-8 layers is adequate. 5) When it cures, take off the board now you have female mould of the left section. 6) Repeat steps 2 - 5 to proceed another section. 7) When both section done, fine sand the inner of the mould, make it even and smoothy. 8) Pour water into the mould to determine the volume. 9) Pour foam agent into the mould. Until it finishs the expansion, take it off then you’ll have the half of the blank. 10) When both left & right foam blank are done, you can glue it with a stringer. Regards, Crabie
Rabbit, I dont have much experience in moulding, pls. correct me if I m > wrong: 1) Use a board you gonna make copies, it must be no ding, no dent, > no damage, seal all the plugs. 2) Divide the board into two section, e.g. > left & right 3) Spread even the release wax or agents to left section > if you plan to mould it first 4) Flip the board horizontally, using resin > + fiberglass to lay on the section, wrap the entire section, normally 6-8 > layers is adequate. 5) When it cures, take off the board now you have > female mould of the left section. 6) Repeat steps 2 - 5 to proceed another > section. 7) When both section done, fine sand the inner of the mould, make > it even and smoothy. 8) Pour water into the mould to determine the volume. > 9) Pour foam agent into the mould. Until it finishs the expansion, take it > off then you’ll have the half of the blank. 10) When both left & right > foam blank are done, you can glue it with a stringer.>>> Regards, Look, I am the first one not to make fun or critisize you guys, but do you ever have it all ass backwards here. ONE, you would never get your board out of the mold you are thinking of making. Two, the blank would be the same size as the board and it would need to be shapable. The money you think you are saving, you would be pissing away in the wind , just buy the blanks from a reliable source. I have been around the US industries foam blowers since the mid 60’s and seen with all their resources the problems that even they incur. Your little fiberglass mold would never withstand the expansion. You will be Del Cannon, only worse.>>> Crabie
Thanks Jim, I only have the experience in making fin mould, upon this subject, just want to test my thought of mould making is rite or wrong, I m gonna not blow my own foam cos I know that its really difficult to adjust the foam density. The issue of pouring water into female plug in order to obtain accurate volume is much crucial in foam blowing. Anyway thanks for your comments. Regards, Crabie>>> Look, I am the first one not to make fun or critisize you guys, but do you > ever have it all ass backwards here. ONE, you would never get your board > out of the mold you are thinking of making. Two, the blank would be the > same size as the board and it would need to be shapable. The money you > think you are saving, you would be pissing away in the wind , just buy the > blanks from a reliable source. I have been around the US industries foam > blowers since the mid 60’s and seen with all their resources the problems > that even they incur. Your little fiberglass mold would never withstand > the expansion. You will be Del Cannon, only worse.
Thanks Jim, I only have the experience in making fin mould, upon this > subject, just want to test my thought of mould making is rite or wrong, I > m gonna not blow my own foam cos I know that its really difficult to > adjust the foam density. The issue of pouring water into female plug in > order to obtain accurate volume is much crucial in foam blowing. Anyway > thanks for your comments.>>> Regards,>>> Crabie Crabie Jim is correct about most things he has said. Making surfboard foam is my life at this time and will not say anything about making it, even if you are wrong or correct about making mould or foam.Rob and i have worked hard and long hours to get the foam where we are now, so i will sell the foam to you at a good price but the shipping cost kills it for me. JR is coming out to Aussie later so i will show him the foam and Resin and he can tell you all what its like. Tom Wagener rang last week to place his regular order and he cant get over how good the foam and resin is, the best resin he has ever used and hes been making boards from day one. Rabbit http://www.southcoastfoam.com.au
Thanks Rabbit, Actually I dont blow my own foam blank and just guess the methodology of making blank mould. Anyway thanks for your reply. Regards, Crabie
I know that everyone on here says to not try to blow your own foam, but i am going to try it anyway and post the results up here. Before i do it, let me tell you what i am going to do. If any expert would like to correct me on how it’s done, then your help/input would be greatly appreciated.
I am going to make a 2-part fibreglass mould of a board (deck and bottom) using gelcoat,chopped strand mat and my offcuts. I am then going to glass on some scaffold poles to each half, and re-enforce that with concrete, attatch hinges and a counter-weight. Togethor with clamps, this should be able to withstand the pressure of the foam.
I am going to glass each side of the moulds with epoxy resin (2x 6oz on the deck and 6&4oz on the bottom) Then pour in the 2-part foam, clamp it shut and watch it blow.
When it comes out, i will sand off and glass the rim running round it.
Now i don’t see how this could go wrong. It should be a basic epoxy sandwich board that pops out.
The only foam that i can get my hands on is the PU 2-part foam from the fibreglass store, and this is my main concern. If anyone knows where i could get any better foam suitable for this project, then please post me in the right direction.
many thanks
I poured blanks for Midget back in the 70’s and each half of the concrete mold was about 12 inches thick and weighs about 500 kilos. To make a 6’6" board you’ll need to make a blank 7 foot and the concrete mold needs to be a foot longer at each end, so now you need a 9 foot mold to make a short board. There’s a starting point for you.
its not impossible to do it but you have to think Industrial size !!
great, well concrete is cheaper than fibreglass, so that’s good. I’m not making a blank, just a popout/epoxy sandwich board. The board is 7"6 so a 9"6 mould would do. This is what i was expecting, cos that foam’s strength needs to be resisted. If you have any more hints/tips on making the mould, then it would be much appreciated. Man, this forum is brilliant. thanks swaylocks
I have made one half of the mould. The fibreglassing part was just like making any normal 2 part mould, then i built a box around it and i have poured the concrete in. It’s gonna be heavy, but i can’t wait to flip it over and do the other side. I will post it up when all is done. It deffinately looks industrial, but wasn’t very expensive at all.