In the previous post we talked about adding the external lamination of 2 oz carbon fiber. In this post we apply the fabric and prepare it for pump down in the vaccum bag overnight.
Our original goal for this board was 2.5 pounds and it will come in significantly lighter, very possibly at or below 2 pounds. So we’ve ordered the materials to try and build a sub 2 pound wakesurf boards.
We like the flexibility of construction associated with a composite sandwich, as we can mix and match fibers, orientations, as well as, materials to achieve the desired results. To us here at FlyBoy Wakesurf, composite sandwich construction is how modern performance wakesurf boards will be manufactured in the future.
We make our rocker bed into a temporary wetout table by laying down a sheet of polyethelene.
We lay out the cut Carbon Fiber onto the “wet out table” in preparation for spreading the epoxy.
The weather has turned cold so we use a microwave oven to “nuke” the resin just enough to increase the viscosity so that it spreads easier.
Well it seems we missed a few shots in here, but what we did is wet out the carbon fiber. It took a bit more than the 1.4 oz we need. Next we laid the wet out Carbon Fiber on the deck of the board. Next we top that with the green’ish perforated peel ply. The perf ply has small holes spaced at about 1 inch intervals that allows excess resin to be drawn out, as well as, any trapped air.
Next the perf ply is pulled tight, by hand, to help wrap the rails and pull the deck lamination down. Then a squeege is used to push out any air bubbles before sliding it into the bag.
Next we wrap the board in bleeder cloth. The bleeder will capture the excess resin that is squeezed out through the holes in the perf ply. We use papertowels because it’s so much cheaper than actualy bleeder cloth.
Finally we wrap everything in an open cell matress topper foam. This foam acts as a breather and intensifier. The breather allows air to pass through it, so as not to trap the vacuum bag with a partial evacuation. The foam allows any and all air to pass through it until it is compressed into a thin layer. It also acts as an intensifier, helping stretch the underlying laminate fabric tightly as the vacuum is drawn down.
Now that everything is assembled it is placed inside a vacuum bag and then pumped down over night. The epxoy is allowed to cure and the project is removed from the bag in the morning.
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[...] In traditional construction, only the shape can effectively be changed. The composite sandwich, as we document in these builds, allows for different shapes, but also every aspect of the core can [...]
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