PVC Rails

General Discussion
1

I have searched the forum as I am sure there is info on what I want to do, but as I could not find anything, here goes:

I am wanting to start with a 1lb EPS core with 3/4" wide high density PVC foam rails. I will use PU expanding foam or Gorilla glue to attach the PVC to the EPS.

Following shaping I then would like to glass this blank with 4 oz or 6oz cloth/epoxy  all over (with extra glass in foot area)

Following this, vacuum down the complete blank with 3mm Airex PVC foam.

sand then  6oz or maybe 4oz finish glass the board.

I know this is a common method of construction, but I cannot think how to shape and sand the hard rails against the very soft 1lb EPS.

Every time I have tried sanding two different densities side by side, I end up with a ridge. maybe this will not be an issue as I will be covering with 3mm Airex???

I will sometimes be using this board (5’10x 18x2, squash tail) with a kite, so it needs to be strong. Any thoughts on how to do this, and glass layup schedule?

 

Thanks

 

Gary

 

2

have you read this thread?:

http://www2.swaylocks.com/node/1012644

also, you might want to PM Kiterider... sounds like this is right up his alley

3

Hi,

I built a board similar to what you describe except I used 1/16" balsa for the sandwich. I put the inner glass and skins onto the core, then added the rails, then the outer glass.

The rails I just cut oversized and used gorrilla glue and a sitck of plastic wrap to glue them on.

It was no problem shaping the pvc up to the relatively soft balsa, probably partly due to the fact that the transitions were located where the shape of the board goes from  relatively flat to very curved.

trent

4

You’ll find all the info you need on sways, but this might save you trolling through:

http://www.compsand.com/compsand-community/forums/index.php?topic=1295

imo don’t use sandpaper on the rails until the skins are on. Blades only, otherwise you’ll have the problems you described.

5

Thanks guys, great help.

‘It was no problem shaping the pvc up to the relatively soft balsa,
probably partly due to the fact that the transitions were located where
the shape of the board goes from  relatively flat to very curved.’

This was my exact thought, so I have made a small piece of ‘dummy’ blank to see how it goes.

My other thought was to make the eps blank 3/4" smaller all round, shape it but keeping the rail square, glass, then stick the 3/4" wide PVC rail band on. The problem I see here is getting the blank shape correct where it begins to curve into the rail.

I