Hi, I hope I don't have too many regulars shaking their heads in shame, but I am shaping my first board and would appreciate any advice from heads more experienced than my own. If not, hey, at least I'll probably leave you entertained thinking about my bold (idiotic, and not-thought-through) ambitions!
More info makes a more detailed picture, but I'll try to keep this as short as I can.
I'm shaping a prone/kneeling board for use in surf lifesaving. Basically, it's a 10'6'' board of width around 20'' and thickness around 7''. They are used for competitive racing (buzzwords: LIGHT and RIGID), however I would like to focus on breaking the laws of physics and attempting to build a board that can be competitive AND durable (most competition boards get damaged quickly the way we race them here in Ireland). As for shaping, I'm pretty much set, thanks to the hours I poured into studying swaylocks instead of my honest-to-god science degree ;) . The basics are: (probably best read bottom to top)
- THE HEART - 1lb EPS foam core (Yeah, it's a BIG blank.. will have to stick two 8' blocks together (using a bit of PU pour foam and ratcheting them until they're stuck)
- THE RIBCAGE - single-layer 4oz Carbon Fibre//epoxy, deck & hull (I want a nice rigid core here, my thought process being: ''punchy'' through waves/chop, instead of the waves causing flex through the board and losing momentum - correct me if this is a waste of time)
- THE FAT - 1/2'' thickness (when cured/set) of 2lbPU pour foam (maybe even 4lbPU pour foam) all over the board, coating the entire thing.. like Mr.Whippy with the raspberry sauce on a good '99, (other references were decidedly removed due to their unholy nature).
- THE CALLOUSES - patch reinforcement of Kevlar/aramid//epoxy on the tail rails, (these boards get pretty abused from being dragged up the sand
- THE SKIN - I want the outer laminate to be composed of 6oz Diolen//epoxy on its own, with a hot coat, MAYBE GLOSS, if I'm feeling groovy (I hear the veteran shapers smacking their lips at me, ready to take their bite - ''BUT WAIT,'' I cry, ''HEAR ME OUT! FOR AMUSEMENT, IF NOTHING ELSE!'')
To my understanding, Diolen is a material with properties of high elasticity, compared to most other laminate materials. ALSO, it is pretty resistant to abrasion, not quite on par with Kevlar/aramid, but much better than glass. Taking the Diolen-over PU pour foam as an outer 'shell', I propose that the board will be:
- more tolerant of high impact/compression as the pliant, forgiving outer shell will (hopefully) flex/deform to absorb the force and (hopefully) bounce back to its original shape, instead of breaking brittly from brute stubbornness, not unlike a regular ol' foamie.
- more water resistant. In the event of the Diolen cracking, the closed-cell formation of polyurethane foam should localise/trap the leak and prevent the board from soaking out.
- given the rigid nature of the carbon core, the high flex of the Diolen should maintain its overall 'shape', (OR should I thicken the Diolen with 1.5oz e-glass (or heavier??), and should the glass lay internal or external of the Diolen?)
That's my food for thought - not quite a meal, more like a snack.. just enough to make you want more. I suppose it's just a different kind of sandwich.
Anyway, as far as I can tell, nobody has made a board like this (probably for good reason, possibly not). If you were in my position, full of mistakes yet to happen but willing to screw up as long as you dont have to peel off all that Diolen and pourfoam and go with the regular carbon-glass single lam instead
WHAT WOULD YOU DO?
(ANY THOUGHTS REALLY APPRECIATED HERE)
Thank you for your replies, I hope you've at least been entertained.
[DISCLAIMER: I AM NOT TRYING TO OFFEND ANY SURF GURUS IN THEIR SHAPING RITUALS. I ONLY WANT TO LEARN, MAYBE EVEN SPARK A BIT OF CREATIVE INNOVATION]