Hollow / Chambered Redwood Board Build

Thought I would share this as I work on it.  My idea is to make a board thats a cross between my alaia and my little 5’6" hybrid fish/pod.  

In the first picture, I have all the redwood 2x6’s cut out.  The rocker templete is on the left with

one of the cross sections next to it.  My plan is to shape the fins into the board that’s why I left so much wood at the tail end.

 Im envisioning long low profile fins.  

In this picture, Im glueing all of the boards together with newspaper between them so I

can easily pull them apart later to hollow them out.  I weighed and sorted the boards first so the

weight distribution would be as even as possible.  

Here I have all the boards glued together and clamped with my home made clamps.  

The board outline is on top.  I already came across my first problem with the clamps.  

They wouldn’t squeeze the boards evenly causing them to fan on the underside.  I’ll

probably go buy some clamps later.  Anyway thats it for now



just put one clamp on top and the next one on bottom. as far as glueing goes you only need a pea size dab every 2’ with boards as straight as yours. looks good.

Recent work.

Picture got squashed.

 

Hi John, I’m building 2 hollow redwood & blue pine stubs next week. Checking out your method to see how it goes. My approach will be different although I am also chambering. Looking forward to seeing your board glossed and surf ready.

I should have added that prior to the picture, I ripped all the boards apart, sanded off all of the glue then stuck them back together with double sided pressure sensitive tape.

Another note, when I cut out the outline, I had not thought about what I was going to use to cut the back of the board.  It’s hard to tell from the picture but the back of the board is three and a half inches thick.  I’ll spare you the details but let’s just say it wasn’t fun and ended up doing a hack job on the tail.

So, when that was done, I thought I got to the fun part, removing all the wood between the fins and establishing the tail rocker.  I used a router on most of it but, its a cheap router with a quarter inch shank so, the plunge depth was not enough at the back of the board.  Lots of manuel labor involved.  I’ll quote my wife who may be wiser than I, she called it a “Waste of time.” Im determined to prove her wrong but only time will tell if its a waste, go figure.

ha! What else is she supposed to say? That’s textbook chicks right there. 

…Yeah, you have a lot of wood subtraction to deal with. Depending on how thin your chamber walls are, you might want to prime the outer walls with resin to ensure their strength–before you chew out the inside and when you do that final re-assembly you’ll have some added strenght on delicate corners. I’m going really thin, my boards will get warp glass and epoxy.

This sounds like a fun project.  I made a similarly shaped balsa/redwood chambered board a few years ago.  Here is the link to the photo set the I compiled for the project.  I haven’t ridden that board in a while.  Seeing your post has inspired me to break it out and start surfing it again.

http://www.flickr.com/photos/swied/sets/72157600387296482/