“D-cell sandwiched between layers of cloth is bombproof. I’ve been doing
that on my last series of decks. Not a single pressure dent. No
footwells, nothing.”
So what is it you do not like about the
d-cell sandwich that led you on this path? Seems like you are going in a
totally different direction than that of a d-cell sandwich which you
describe yourself as “bombproof”. That seems to take care of #2 of your
requirements, then you need to work on the #1 - flex and #3 - cosmetics.
You mention stringers in your flex equation. As a contractor I’m sure you are well aware of the significant differences between individual pieces of wood. This can be a big unknown in surfboard flex. By eliminating the stringer and replacing it with some sort of cloth, which tend to be made in highly controlled conditions to ISO standards, then you can greatly regulate your flex.
Also, remember that epoxy resin comes in different flex modulus, so if you find a “bombproof” build but it is too stiff, you can alter that buy just using a different epoxy.
Your sample experiments are interesting and will give you a better understanding of how the materials work with your desired materials, but they seem to be missing the larger context of a complete surfboard.
Just to throw something out there on your #2 requirement too, about price with regards to this comment:
“Marketing price point equilibrium would be making a board that lasts twice as long, and costs twice as much.”
I can tell you from experience in the retail space, that making a board that lasts twices as long you will be hard-pressed to get a $100-$200 premium over a standard poly board. It will require a massive marketing expenditure to even validate that price to the average customer. Remember, surfers are inherently cheap. There are pleny of examples of this in practice currently - Firewire, Coil, Surftech, probably hundreds of smaller shapers offering alternative tech builds. It’s rare to see these offered at more than a $200 premium, much less double. At double the retail price, you’re not going to sell any boards. Throwing expensive tech at it isn’t going to validate that price. Boards snap, period. 1 photo of your board snapped will invalidate all the marketing money that was spent on convincing your customers your boards are stronger/more durable and therefore worth the premium.
The key factor is performance. If you make a board that rides better, and as an added side-benefit is more durable, you’re going to do well.
I think this was the point you missed in the initial “train-wreck” thread that was trying to be made that you took offense too. The delivery may have been off, but the point was valid.
I’m all for what you’re doing, as I have ridden bamboo/cork/stringerless boards myself for years and am totally sold on the performance/durability of alternative build methods. All my boards are vac-bagged now and have been for quite some time. If nothing else, the inclusion of bagging into the build method increases strength due to better resin/cloth ratios.