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05.07.2021, adminThe building of a fiberglass xps foam skimboard varies from company to company. Different skimboard crafters have different techniques and processes. The challenge was hard but ultimately very fun once I got the process. My top suggestions before you start on this project is that you have patience, practice proper safety, and work slowly and accurately.
Don't get discouraged if the materials are hard to work. The most foam core fiberglass boat building app steps are the first ones. Good Luck! Here we go! The first step! The absolutely most affordable quality foam option available at your foam core fiberglass boat building app is from Lowes hardware store. Expanded Polystyrene.
This stuff is waterproof, lightweight and cuts very clean. The dimensions are 0. But after all the layers of epoxy and fiberglass you'll get a thickness of around 0. This sheet is enough to make 3x55" skimboards if angled correctly.
Plenty of material in case you botch a first or second attempt. I created a stencil and had it printed on Vistaprint. The board I created was for a 55" tall by 22" skimboard. I used the stencil after cutting it out of the sheet on the board and marked the outline with a marker.
I repeated this for the foam core fiberglass boat building app half of the foam. Here is the adobe illustrator file of my stencil as well as the jpg if you want to order a large format stencil from Vistaprint. I then used a box cutter to cut out the shape from the foam making sure to have a very byjus class 10 maths chapter 3 excel vertical angled cut.
Try to create a smooth bevel only eliminating a small portion of the foam. I highly suggest at this point getting byjus class 10 maths chapter 3 excel breathing mask to not inhale the dust from this foam. Underneath the front tail place a round object with the right height that you'd like the front bend to make. I used a broom handle. I did a 20 degree angle bend. Here comes the hard.
Using a foam core fiberglass boat building app gun very lightly in short passes I was able to make the bend maintain it's shape. I don't recommend putting the heat gun less than 1 foot over the foam board.
YOU don't want this to burn or melt! It takes light passes several times to have the foam keep the bend shape. Do this part slowly and cautiously with a mask. Using a Trestle similar to this you want to securely attach the foam board to the base similar to the diagram using this type of thick masking tape.
Make sure the tape is on strongly so that the board does not fall off. You'll be using this masking tape throughout the whole project so buy plenty. DO NOT use blue painters tape or frog tape. This generic masking tape is strong and is more secure for edging later on in the project. Now that you have your skimboard securely attached to the Trestle it's time to edge your board to keep future usage of Epoxy resin from dripping underneath the board in the next couple steps.
When you edge with the masking tape same as the mounting stage you protect the bottom of the board from epoxy drippings but also save yourself from having to do excessive sanding around the edge later on. Very important: When you place the tape on the board make sure to edge the very bottom base edge of the board not underneath the board Later on this tape will be removed hopefully leaving a clean line.
I suggest and have used 4oz fiberglass cloth from this place Greenlight Surf Supply. These guys deliver high quality fiberglass cloth at very reasonable prices and they ship practically overnight. Fiberglass Cloth 4 oz x 30" wide x 7 Yards worked for me and gave foam core fiberglass boat building app enough for 4 layers total which is what I needed.
This is where intricate detail is required when cutting and trimming your 4 layers from the cloth. Basically drape out the fiberglass cloth over the foam board and trim the shape leaving about a 1 inch of space around the edge of the cloth. Take your time, and cut very slowly and acurately. Don't worry too much about fraying the edge but just try to create a clean cut around the edge making sure to do 1 inch of excess cloth. You will need a very sharp Exacto knife later on in the epoxy portion of the project.
The fiberglass should drape nicely off the edge of the board overlapping over the masking tape. Epoxy is foam core fiberglass boat building app resin that binds and hardens the fiberglass in to a tough shell on the skimboard. It's very important to stir this thoroughly. I used this Epoxy Resin because of it's affordability and quality but other surf suppliers might recommend other brands.
They also deliver very fast. This 1 gallon epoxy resin is more than enough for the rest of this project. I bought more later for a thicker coat but this should work fine.
These cups are great for mixing epoxy and are disposable. The amount of resin that worked for me for the first layer of epoxy is 2oz of part A and 2oz of Part B. Safety: Wear a breathing mask, nitrile glovesand try to work in a ventilated area. I also encourage byjus class 10 maths chapter 3 excel protection. OK so this is not necessarily needed but it's highly recommended. A Vacuum Chamber uses a compressor to remove bubbles by suctioning out the bubbles that show up after mixing the two part epoxy resin.
I bought my Vaccum Chamber from here and it's reasonably easy to use but do follow the directions on how to use it. This video explains clearly how to do this but it takes a lot of attention to detail to make sure it is done correctly.
Your resin when pouring on to the board will be crystal clear with no bubbles. The other option is using a heat gun to target bubbles after it is poured which works well also and is a cheaper option.
Once your epoxy is mixed and optional vacuumed for bubbles comes the pouring. Place both layers of fiberglass cloth over the board. Make sure the cloth is aligned exactly with a 1 inch overlap even on all edges. Pour the resin on top of the byjus class 10 maths chapter 3 excel making sure there is an even coat. I prefer using a disposable paint brushes like this but a plastic squeegee also works fine. Slowly spread the resin and make sure every inch of the fiberglass is covered.
Make sure to make it drip off foam core fiberglass boat building app edge as the fiberglass cloth edges needs to be coated. The masking tape will pick up the excess dripping of Epoxy resin. Basically cover every bit of the fiberglass cloth leaving no dry areas.
Layer 1 of 2 is. Safety: Wear a breathing mask, nitrile gloves, and try to work in a ventilated area. If you don't have a Vacuum Compressor you can use a heat gun to pass over the board lightly to make sure all bubbles are eliminated. Bubbles will add many cosmetic effects to the cured resin on your board. Even with polishing they can still be visible. It's very important after the 2 layer epoxy pour that you let the second layer cure for about 2 hours. You want to check for a tacky, sticky coat and that signals that the edging tape can be removed easily before it fully hardens.
If you wait too long the tape will be harder to remove. Using your very sharp Exacto Knife you want to cut just above the masking tape in to the fiberglass cloth and then carefully remove this excess layer with masking tape. The harder the cured epoxy shell the harder it is to cut the fiberglass. The diagram shows the cut line recommended.
After the tape and excess fiberglass layer is removed with the Exacto knife let the top layer cure overnight or for more than 4 hours. This is where being patient is key. The fiberglass layer should be hard and dry. If that is the case then you can flip the board and repeat the process of taping the other size of the board to the Trestle.
The masking tape at the bottom of the board securing it is very sticky so remove carefully. Make sure once again that you will be overlapping the next layers on top of the top layer of the board.
Like the diagram:. You want the bottom layer of fiberglass to overlap the top layer of the board so the entire board is bonded. Once you've got that hard shell of epoxy and fiberglass cured it's time for prepping the board for glassing where you will be a nice smooth coat of epoxy on each side of the board. For my board I used a hand sander byjus class 10 maths chapter 3 excel this process similar to. You want to sand out any imperfections using a medium grit.
Polish the nose of the board, the rails, the edges. You won't get it perfectly smooth but enough to get out any big imperfections.
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