Ok ok ok, no love notes, but c’mon you opened this article so that has to be good!
In the previous post we talked about how we liked timber in a prototype wakesurf board. This is NOT the veener that the other Inland Surfer wakesurf boards use, but instead 3 mm thick pieces on the rails and bottom. In that referenced post we had laid out two of the 3mm sheets of basswood. As we mentioned basswood is much more dense than balsa and also has a great deal more memory or “snappiness”. This is good for generating pop off the lip, but a serious pain in the butt when trying to glue it up by hand on wakesurf boards. We didn’t want to ruin the wood or the core, so we opted to glue up two sheets on a side at a time, saving the other two on each side for a second glue up. We found that attempting to bend that much was causing us too much grief as we wrestled with tape, epoxy and vacuum bags.
So, when we go to bag the first two pieces down on the rails, we want to rough cut the rocker. If we don’t we develop two problems. The first is that at the nose where the extra material extends beyond the core, the vacuum bag tends to pull the end down towards the core and as such, the bottom AWAY from the core. Also all that extra material tends to capture the vacuum bag between the core and the basswood. So, the first thing we do is mark up one piece for each side, with the rocker and then cut the rocker into each piece using a scroll saw. We’ve cut one of the sheets and marked another.
We transfer that one cut to the remaining three sheets and prepare them for cutting.
The nylon bag we are using is pretty strong, but when we are pulling 10 inches of vacuum, the pressure is tremendous on anything sharp or pointy. So we hit EVERYTHING with the sanding block. No splinters and we round over all corners.
In the next post we’ll slater everything with epoxy and start the glue up.
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