Shop class

so in my engineering design class we have to build a project. some kids are (going) making a trebuchet, some are(planning to) making a hover craft. I figured why not make a surfboard. My teacher is really pushing us to do some engineering and though i am stripping my first board(clark foam) i made to make a fish, I really want to do something a little more technical. I want to make a compsand. here are my planned supplies.

the smallest vaccum pump on fiberglasssupply.com

balsa

1lb eps blank from segway

r r 2040 epoxy

the lightest e glass i can get

fcs plugs.

planer files brushes etc

vacuum bag.

what else will i need?

I am going to search the archives pretty thourghly for design ideas.

many thanks,- Kyle A. Dexheimer

Sounds like fun,

Why not make a vacuum pump (JoeWoodworker.com).Or use a refrigerator pump.

This is an broken compressor tank and fridge pump with an auto shut off & vac gauge.

Cost under $50 and works great.

Get the $12-$15 3yrdx50" sample packs of light glass from Thayercraft.com,call and ask

what is best for a surfboard.

RR2000 or 2020 if you want flex.

If you want to make it more technical look up the $14 dollar blank thread and

make your own HomeDepo blank(don’t use Elmers white glue).You will need to use some thing to beef up the 1lb foam

for the fcs plugs HD foam or balsa.

For one board no planer is needed,+not so good for1lbEps. Just some 40grit sand paper

and wood or wire brush.Support the blank with an old surfboard under when shaping.

You can get balsa from hobby stores 3x1/4" for rails and 3/32"-1/16" skins.Glass over&under.

Get a good bag and sealer tape for the bag.Fiberglas supply.com.Micro balloons to seal blank,

lots of tape,rags,denatured alcohol,rubber gloves,and shop vacuum.

Have fun,

Ian

Ian got it all.

And the important piece, like he said and in case you missed it, is use RR 2000 or 2020, not the 2040 you had planned…

Ken at Segway is a great resource, has a superior product and unbelievable customer support. He will probably throw in the high density foam to use around the FCS plugs (use gorilla glue to put in these inserts).

With 1 lb foam (and no stringer) you will probably need a “rocker table” of some sort or the blank might flatten out under vac. Ask Ken

Check ebay for vacuum pumps. I found the fiberglasssupply ones pricey and maybe not necessary unless you plan to go into full time production. Look for a pump rated 24/7 continuous duty, with vacuum gauges and bleeder valves so you can forgo all the vacuum reservoir, vac switch and check valves, which to me seem very expensive and complicated.

The top of a glue bottle works great as a vac hose attachment- fits the shop vac for initial pull and the 1/4" hose for final pull (search my “EPS plywood fun gun” thread for photos).

Don’t forget bubble wrap to use for a bleeder. Additionally I used some heavy sponge right under the hose attachment so the hose doesn’t just suck down at the attachment point.

ok. I like the idea on the fridge compressor. How do you make that? I am getting rid of fridge(still runs fine just old and smells bad). And i have al;ready worked with Ken on one project and he has great customer serivce and I wam going back to him for all my EPS needs

Look up the (cheap little sucker) thread.

Some great info on vacuum pumps.

Basically fridge compressor on the suck side copper tube JB weld to T fitting $18 vacuum gauge.

Then a bolt for vacuum pressure control and tube to bag.On the blow side leave extra

copper tube.Coil it up and connect to a bottle with holes in the top to trap the oil.Add a little

oil every time you start it up.

If you want to make a more complicated version go to Joewoodworker.com

Good luck,

Ian