Feb 05

Composite sandwich compressive strength

Did your team win the super bowl? Ours didn’t but it was a great game. The second half was wild and riveting! We wanted to take a minute and revisit the series of photos of James Walker winching the production Flyboy. Just as a refresher and for folks just joining us, here is that picture we are talking about.

closeup winch

James was able to grab the winch and Flyboy Wakesurf board back from the site. He had left it there over a weekend, as he originally planned to winch a second day with all manner of other folks, but he was called away with other obligations. Rather than spoil that fun, he left the winch with friends. You can see the winch, James’ wakeskate and our production Flyboy. Plus all the mud and gravel stuck on the back of the Flyboy!

No damage 001

So it’s scratched up, as we’d expect after sliding over a wooden rail, but no breakage. It’s still intact and is ridable.

No damage 002

The deckside is fine also, save for the mud and gravel on the kicktail!

No damage 003

Sliding a rail is ridiculously abusive for a wakesurf board, they just aren’t built for that sort of thing, but as you can see the Flyboy Wakesurf board’s composite sandwich construction is tough enough to withstand a least a limited amount of that abuse.

The composite sandwich that we use has a tough outer shell of high density foam, wrapped in fiberglass and outlined with carbon fiber. That foam has a density of 5 pounds per cubic foot. Most high performance wakesurf boards that are currently available use a 1.5 pound density EPS foam. EPS is an open cell foam, but also is 1/3 the density of the skin we use on the Flyboy wakesurf board. Not only does the lower density eps dent much easier, it’s compressive strength, compared to the high density foam we use is 2/3 weaker. Hitting a rail with that foam would create dents, very possibly breakage upon the first impact. Not so with the higher density and stronger 5 pound density foam skin we use on the Flyboy Wakesurf boards.

Now higher density foams could be used throughout, but that increases weight over all and the interior or core of the wakesurf board is heavier than it needs to be. Often times creating a wakesurf board that feels dead or lifeless.

So again, we do NOT recommend that you hit rails with your Flyboy Wakesurf board, but it’s good to know that you can and that the Flyboy Wakesurf board can handle pretty much anything you can throw at it wakesurfing. Also, we like the out-of-the-box demonstration of the rugged composite sandwich construction.

Thanks so much for following along! We really appreciate it.


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