Hello , I have been reading and thinking about the EPS hype and have a question?? Is being light allways the answer ? Why not make boards hollow? 1-2 lbs total? Don’t get me wrong I am a real proponet of EPS. I have an 10 footer Forstall eps/epoxy and have had 3 others from him . My favorite board also happens to be a 9’6" Walden Magic Boardworks . Early model . No stringer and very light … It just seems to me that sometimes the “feel” that I get from a poly / PU board is better . Maybe it’s just the shape I get / order… But they seem too light-mushy?-no feel… I wonder if anyone else has had this happen to them . Like I said maybe it is just from the shape that I ordered… But if light is the end all of board building why not make them hollow ? I just feel that theirs something to be said for the poly/PU boards too…
Hotcoat…
Building a hollow board has its challenges. There are several way to go about constructing hollow boards, they can be done via open tools, which is what I do, they can be done in a tool with an inflatable bladder, or even done over a mandrel such as a salt cast, then dissolve the salt. These are just some of the ways the boards could be built. The problem is maintaining the strength while minimizing the weight. Building a 2 lb board can be done, but strength would be sacrificed in the process. The stresses put upon a board are substantial, and the board has to have proper flex, yet be strong enough to take the beating of landing an “air” and still not leak! Not much to ask!
In order to maintain the strength, one option is to change the material, hence carbon fiber and epoxy. In order to give the structure support, a core material must be used to sandwich the lamenates, and this is where the various core materials come into play. This can be accomplished with foams, wood, and honeycomb materials. Sandwich construction is one of the most effective ways to build strength into a product, and keep the weight to a minimum, just ask Bert!
Working with and building the necessary tooling is a slow labor intensive process, as well as expensive. Tooling for a single board starts in the 4K to 5K range, and goes up depending on the material used for the tooling. In addition, the cost of the carbon has jumped from 10 to 12 dollars per yard to 30 to 50 dollars per yard. The aircraft certified aluminum honeycomb I use can cost as much as $ 300 per 4X8 sheet if purchased in small quantities. So building a quality hollow board is not for those wishing to watch their wallets!
I think the option for most backyard and production shops would be the EPS/epoxy choice. Because the margins are so low on surfboards, costs must be kept to a minimum, and production done efficiently in order to make the business profitable. The other option is to custom build high quality boards with limited production and keep the margins high. In order to be profitable with the needed tooling of the hollow board, the cost of the tooling must be amortized into the cost of the surfboards divided by the life of the tool.
In order to satisfy both markets, I have tried to support both technologies with the EPS blanks and KOLSTOF hollow board nitch market. I think the materials will continue to push more performance advancements into the surfing industry, and the cost reductions will come with better processes. I have been blessed to work with some of the most respected and kowlagable,forward thinking people in the surfing industry. I just hope I can keep up and contribute to the ongoing advancements!!!
Ken
Thanks Airframe… Lots of good Info. there . What I was asking about was the difference in the “feel” of a poly board compared to a EPS / Epoxy one … This has probabally been discussed before . The thread about new EPS Tech got me thinking about it thou… I have … or had 2 boards exacty the same 8 ft. funboards and when it came time to get rid of one of them … (Too many boards) the EPS / Epoxy one went . I just liked the feel of the poly board better . And yes I think it was a little thicker and a little wider… The guy who copied it for me did a great job and took in consideration making it thinner… I just felt the poly board rode better … Had more “glide” for one thing … Anyone else had this experience? Or has this already been beaten to a pulp as a topic?? Aloha , and Thanks… Don
Don…
Construction aspects of surfboards is very interesting, and new designs and materials are always fascinating. And I would be remiss not to mention the wonderful craftsmen that build those hollow wooden surfboards that are works of art!! The most important thing is riding what works for you and enjoying one of Earths pleasures!
Ken
a buddy of mine makes hollow boards. Check out his web site. Not real informative, but if you can spare $1000.00+ I hear they are pretty good boards.