Why not glass as normal? Lay the cloth over the whole thing, cut out the inside leaving enough that you can do laps, and make relief cuts so that the you wrap all the laps.
I wouldn’t do it like a plaster cast because the maximum length of the fibres along the length of the board is only the width of your cloth strips (looks around 75mm?). Your tensile capacity will be greatly reduced. I’d probably attempt to glass it like a normal board and try to glass the inside of the cut-out just like another rail wrap.
However you glass it, keep in mind that it may want to twist and warp the way a flexspoon will (during glassing second side, once the mass of the foam plug is removed). Not sure how I’d address that issue with this creation as it is already “unstable”. When I made flexspoon I glassed bottom of solid foam plug (shaped mold), removed the foam and used hot glue to tack the wiggly glass bottom down on a sheet of braced plywood. Then after filling and shaping the rails w/ pour foam, glassed the deck. Even then, I popped it free of the glue too soon, after resin was hard but not fully cured, and it tried to twist itself around long axis. Fortunately I sort of had an eye on it and got it tacked back down in time and after it cured it stayed the way I wanted it.
10,000 thank you’s to Dale Solomonson for warning me in advance of the issue and giving me tips on dealing with it!
I figured it was something like that, but I imagined a fiberglass or plexiglass bottom. You're saying no bottom other than what you see? Definitely pushing the envelope!
surffoils the first [but not the last !] to surf a toilet seat ...
it would really have made a statement , back in the 1970s , at Wind'n'Sewerage Boardriders comps , I think !!
my brother won a sh**load of 'gopro' stuff , by taking a photo of himself [fully dressed , thankfully !! ] looking at the camera [yep , floating in his toilet !] ...imaginative , but not quite on a par with your " Bauhaus meets acid ... and, Brett takes it surfing" shenaningans ...
...I mean , REALLY , HOW can anyone say 'this place is "BORING" ??!!!!
....come on , pay more attention , you critics !
.....there is usually SOMETHING a little bit whacky or left field / out of the planet / box going on , here at sways , sooner or later ?!
[and you've just upped the ....er .... ant[e] now , Brett !! ....well DONE !]
I , for one , can't wait to see 'the bowl' , slotted in [perhaps] a Bower or D.Y. P.... bowl !
I vacced 2 layers of 12 oz Innegra over it.. I might leave it at that, if it snaps I can make a higher tech version. I want the whole thing to flex so the fabric can morph under load from the wave.
give it to derek to ride finless at the point or l.a. , and put a pair of 'grange ' fins on it for tommy gun to do his patented er 'snaps' at peter crawford's old stomping grounds brett !!
and of course , get photos or footage if that ever happened eh ?!
So Ive vacced several layers of Innegra over the whole frame, cuz theres no stringer or real thickness to the foam I had to beef up the glass to give it enough strength.
Moving forward with the build Ive been thinking whether its better to use a flexible or non flexy material to cover the frame. I chose flexible but now I think I chose wrong. I wanted the hull fabric to morph under pressure and create its own concave or hull shape based on the applied water frorces.
Problem is that the flexible material has some stretch and it stretched... The tight skin is now not so tight, may as well have used an inflexible material and just left a bit of slack in it. I'll still go thru with the testing of the current material but Ive found a megalight 30 denier ripstop fabric thats about 1/2 the weight of some mat material and I can glue or heat-seal it.
next is to put in an inflation tube/valve and the deck skin and then test the beast.