Back to the super thick skimmer build out! As you no doubt remember, we have glued a few sheets together and made a patch work up at the nose, because we just scraped this project together. Now we are going to cut the outline and do the basic rail shaping at the same time. This is a little different than dealing with lower density foam or even high density rail material that has rail bands that extend onto the deck of a wakesurf board. We wanted sharp rails all the way around, but also nicely curved at the top where it met the deck.
As you can imagine, the rails will be slanted inward from the bottom to the top. We wanted to make quick work of this, and got the idea that if we set the blade on our jig saw at 60 degrees, as we cut the outline, we’d do just that! Set the first “rail band” and trim the outline at the same time.
It’s a little hard to see, but here is what it looks like after we cut the outline on one side. If you look closely uou can see the angle inward from bottom to top.
This gives a much better view of the angle of the rails after the outline cut.
The rest is fairly normal rail shaping; sanding block and planer to arrive at nicely smooth and rounded rails on the deck surface. We marked the inside of each rail band and then shaped up to that mark, so that we had nice uniform rails. You can’t really tell it from this picture, but we filled in a gluing error at the nose and then also tapered the nose down some, so that it wasn’t an inch + thick!
Solid panels of divinycell doesn’t shape that well with a planer, the blades tend to chunk out large sections, so really shallow passes are the key to success. We typically use 1 mm when we can and then just do LOTS of passes to get to the final shape. In sanding we start with 36 grit and usually will finish around 50 grit.
So there you do, that’s the rough shape. We’re kinda thinking about how we want to finish up the rails on this thing. We know that many folks opt out of traditional skimmers because they are too squierrelly. As we’ve mentioned, we’ve seen some horrendously shaped pro-models that we’re sure only a handful of folks can ride effectively and we’ll never do that with a flyboy. It has to be suitable for the a large market or what’s the point?
Stay tuned as we share our thought process in this R&D project! Thanks so much for following along, we really appreciate it.