Let me say to any of you that have ever harbored the thought of TRYING to pour your own foam, think of the worst surfboard building disaster you've had and multiply by a hundred. Do you remember Bopal India, site of a Union Carbide plant, where thousands of people were killed when an accidental cyanide release occured. They were producing a chemical at the plant that is called TDI, a crucial chemical in Polyuerethane foaming resins. When it reacts, it gasses cyanide, foam as it expands, exerts hundreds of pounds of pressure. The molds are solid concrete, reiforced with steel and outfitted with hydralic clamps to keep them shut during the actual "blowing" of the blank. Mold release paper has to be used to keep the foam from marrying the mold. And least of all, the foam must be poured without being filled with more holes than foam. Why do you think there are only 2 polyuerethane foam surfboard blank builders in the US. They are professionals and we still get blanks that have problems,ah, go ahead, give it a try. Whatta' ya' got to lose.
I would like to see the PU foam board builders shift their production plants to China, it'll cut the cost by 50% or more. Hope that the retail price of it will cut down to 50% off~~~~~... P.S. 50% off + originally products. Regards, Crabie
>>> Let me say to any of you that have ever harbored the thought of TRYING to > pour your own foam, think of the worst surfboard building disaster you've > had and multiply by a hundred.>>> Do you remember Bopal India, site of a Union Carbide plant, where > thousands of people were killed when an accidental cyanide release > occured. They were producing a chemical at the plant that is called TDI, a > crucial chemical in Polyuerethane foaming resins. When it reacts, it > gasses cyanide, foam as it expands, exerts hundreds of pounds of pressure. > The molds are solid concrete, reiforced with steel and outfitted with > hydralic clamps to keep them shut during the actual "blowing" of > the blank. Mold release paper has to be used to keep the foam from > marrying the mold. And least of all, the foam must be poured without being > filled with more holes than foam.>>> Why do you think there are only 2 polyuerethane foam surfboard blank > builders in the US. They are professionals and we still get blanks that > have problems,ah, go ahead, give it a try. Whatta' ya' got to lose. Just using Great Stuff(exanding foam in a spray can for insulating) is a pain in the ass.
Did you see, or have seen that Bruce Brown Movie (I think it was Surf Crazy, or Water Logged, or Hollow days) when Del Cannon breaks into the Walker factory looking for a blank. When none were there he tries mixing his own. That setup was crazy, counter weights and hand clamps. It is a wonder how they got any decent foam to work with back then. I guess when it is your setup you get it wired. Even though it was a bit corny it was a very cool look back.
>>> Did you see, or have seen that Bruce Brown Movie (I think it was Surf > Crazy, or Water Logged, or Hollow days) when Del Cannon breaks into the > Walker factory looking for a blank. When none were there he tries mixing > his own. That setup was crazy, counter weights and hand clamps. It is a > wonder how they got any decent foam to work with back then. I guess when > it is your setup you get it wired. Even though it was a bit corny it was a > very cool look back. Hi guy I pour about 80 blanks a day in concrete moulds, Mix all the chemcials every two weeks if i can do it anyone can. I also make the moulds. Its not that hard but it has taken year of failures to get the moulds and foam correct. http://www.southcoastfoam.com.au
about shipping and currency conversion for your fin sets. I know it is not a big order, but I would like to try them out. I don't want to seem sketchy on the process, but how is it handled with some of your overseas clients? I would like to try some of that hard foam you have as well, but I don't know what shipping would be like. It would be hard to justify if it was a lot of $. I am close to the clark hub in FL.
>>> Hi guy I pour about 80 blanks a day in concrete moulds, Mix all the > chemcials every two weeks if i can do it anyone can. I also make the > moulds. Its not that hard but it has taken year of failures to get the > moulds and foam correct. As Rabbit says it has taken a year to get it right and that was on a commercial venture, knowing the dangers and problems first. Commercial surfboard foam has been pre engineered with light stabilizers and other secret tweaks, not just a mix and pour insulation/boat foam. Building the molds is an art in its self
Rabbit, I dont have much experience in moulding, pls. correct me if I m wrong: 1) Use a board you gonna make copies, it must be no ding, no dent, no damage, seal all the plugs. 2) Divide the board into two section, e.g. left & right 3) Spread even the release wax or agents to left section if you plan to mould it first 4) Flip the board horizontally, using resin + fiberglass to lay on the section, wrap the entire section, normally 6-8 layers is adequate. 5) When it cures, take off the board now you have female mould of the left section. 6) Repeat steps 2 - 5 to proceed another section. 7) When both section done, fine sand the inner of the mould, make it even and smoothy. 8) Pour water into the mould to determine the volume. 9) Pour foam agent into the mould. Until it finishs the expansion, take it off then you'll have the half of the blank. 10) When both left & right foam blank are done, you can glue it with a stringer. Regards, Crabie
>>> Rabbit, I dont have much experience in moulding, pls. correct me if I m > wrong: 1) Use a board you gonna make copies, it must be no ding, no dent, > no damage, seal all the plugs. 2) Divide the board into two section, e.g. > left & right 3) Spread even the release wax or agents to left section > if you plan to mould it first 4) Flip the board horizontally, using resin > + fiberglass to lay on the section, wrap the entire section, normally 6-8 > layers is adequate. 5) When it cures, take off the board now you have > female mould of the left section. 6) Repeat steps 2 - 5 to proceed another > section. 7) When both section done, fine sand the inner of the mould, make > it even and smoothy. 8) Pour water into the mould to determine the volume. > 9) Pour foam agent into the mould. Until it finishs the expansion, take it > off then you'll have the half of the blank. 10) When both left & right > foam blank are done, you can glue it with a stringer.>>> Regards, Look, I am the first one not to make fun or critisize you guys, but do you ever have it all ass backwards here. ONE, you would never get your board out of the mold you are thinking of making. Two, the blank would be the same size as the board and it would need to be shapable. The money you think you are saving, you would be pissing away in the wind , just buy the blanks from a reliable source. I have been around the US industries foam blowers since the mid 60's and seen with all their resources the problems that even they incur. Your little fiberglass mold would never withstand the expansion. You will be Del Cannon, only worse.>>> Crabie
Thanks Jim, I only have the experience in making fin mould, upon this subject, just want to test my thought of mould making is rite or wrong, I m gonna not blow my own foam cos I know that its really difficult to adjust the foam density. The issue of pouring water into female plug in order to obtain accurate volume is much crucial in foam blowing. Anyway thanks for your comments. Regards, Crabie>>> Look, I am the first one not to make fun or critisize you guys, but do you > ever have it all ass backwards here. ONE, you would never get your board > out of the mold you are thinking of making. Two, the blank would be the > same size as the board and it would need to be shapable. The money you > think you are saving, you would be pissing away in the wind , just buy the > blanks from a reliable source. I have been around the US industries foam > blowers since the mid 60's and seen with all their resources the problems > that even they incur. Your little fiberglass mold would never withstand > the expansion. You will be Del Cannon, only worse.
>>> Thanks Jim, I only have the experience in making fin mould, upon this > subject, just want to test my thought of mould making is rite or wrong, I > m gonna not blow my own foam cos I know that its really difficult to > adjust the foam density. The issue of pouring water into female plug in > order to obtain accurate volume is much crucial in foam blowing. Anyway > thanks for your comments.>>> Regards,>>> Crabie Crabie Jim is correct about most things he has said. Making surfboard foam is my life at this time and will not say anything about making it, even if you are wrong or correct about making mould or foam.Rob and i have worked hard and long hours to get the foam where we are now, so i will sell the foam to you at a good price but the shipping cost kills it for me. JR is coming out to Aussie later so i will show him the foam and Resin and he can tell you all what its like. Tom Wagener rang last week to place his regular order and he cant get over how good the foam and resin is, the best resin he has ever used and hes been making boards from day one. Rabbit http://www.southcoastfoam.com.au
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