I did this once before and said I’d never do it again. Well, “never say never”. So here it is. I learned a lot the last time and this went much easier.
After installing the plate using my high tech clamping method I had the glasser, Marc Rhodes, just glass over the insert. Then taped it off, sanded a little and using a box cutter, cut the slot for the fin.
Complete build photos here: http://www.balsabill.com/Osvaldo%27s%20Board.htm
I have to say well done and bravo! Just that little bit extra takes away that plastic molded feeling and screams custom.
Wow, that’s great!
good job!
Aren’t there any issues with water intrusion on the insides of the balsa cover?
That looks great. Did you seal the balsa over the box?
Bill, I am pretty sure you also said you wouldn’t build anymore balsa boards? Which I thought was odd. But love it that you still use the Harbor Frieght planer. Shows it is the talent, not the tool that makes it right.
Did you surf Tuesday?
Should have included this photo. The insert is completely glassed over when the bottom is glassed. Then I cut the slot with a box cutter (see above) after sanding a little of the resin away.
The balsa veneer, which I bought at the local Ace hardware store in the model dept, was only 1/16" before I sanded it flush.
When I cut the slot I saw that the resin had completely saturated. the thin balsa veneer. I don’t expect any intrusion. I got a second opinion from Carl Beaulac at Rainbow Distributing in Indian Harbor Beach.
I figure on a project like this which I’ve never seen done before (except the one time I tried it) it’s best to get lots of advice and help.
Mike Daniel gave me a lot of encouragement and help on this whole project too.
now thats just bitchen
nice work
Actually I don’t use a Harbor Freight Planer. I did have one and I bought it for one feature only: The exhaust chute that was switchable side to side. Used it for outlines after a several mods. I ended up throwing it away though.
The planer I use, and have used for years is the Black and Decker. I have a couple. It’s cheaper to buy a new one than hassle with changing the blades or replacing the belt when it breaks. I bought the last one new on Amazon for around thirty bucks.
And this is my last balsa board. Except for the one I’m making for myself right now. There won’t be anymore after that. I really am retiring. I’m getting old.
Did I surf Tuesday? I can’t remember. I told you I’m getting old.
Have had some great days over the last couple of weeks though. Glassy. Nice size.
The last one… I’m not sure your addiction to balsa dust will let you quit…
Great job of channeling your inner Jim Phillips when shaping this one.
Fin box detail is super-cool.
Looks great Bill. I’ve always wanted to make a balsa board but can’t source it here in NS. Some day…
Just for clarification:
Did you route the hole and then mark and grind a standard Fins Unlimited box down before setting it with resin? It looks like you have countersunk the box 1/16 below to allow for your balsa insert.
Exactly, Had George Surf Guy Jones do the router work since I’ve never done that before. Glued in the box, fin in, and lined it up to make sure it was straight.
The standard box routing jig he has leaves a little play for glass which I didn’t use so there was a little gap. I did a little shimming to get it straight.
I ground off the top of the fin box with just under 1/16" countersunk so I could sand the veneer flush. I had to do two to get it right.
I just glued it in with Elmer’s version of Gorilla glue. I didn’t use resin under the box for a variety of reasons.
Thanks Mike.
I channeled my inner Jim Phillips for sure. Also Floyd Smith, Larry Gordon, Skip Frye, Paul Bordieri, Mike Diffenderfer, Rennie Yater, Dick Brewer and Donald Takayama all of whom have given me bits of information on shaping this type of board.