In our last post we showed the rough cut of the two different types of foam and then talked about resin infusion and also the idea of how we will lap the rails on the construction of this triple density wakesurf board core. In a previous we did talk about how we will lap the rails of this multiple density foam core. Principally what will be happening is the laps will go in different directions, that is the first will lap upwards, the second will lap downwards, etc. Each succeeding layer will alternate in a different direction, up, down, up, etc.
So as you noticed, no doubt, in the last post with the pictures, we showed the two layers of foam a low density EPS bottom and a higher density XPS deck. However, they were relatively rough cut and need to be matched along the outline. So we used a few clamps to hold the two pieces together and broke out the sanding block to match the two pieces of foam. Don’t forget to mask up!
XPS sands really well and being a closed cell foam, it is continuous, so we don;t have to worry about torn beads or anything that would leave a mis-shaped edge or rail.
After the outline is mated, we have to focus a little on the nose area. The nose of the board thins out relative to the rest of the board, so we have to shape that in before the glue up of the two pieces. We should note that we plan to build up the rails of this board, so those will have the rail shape itself. Here is a picture where you can see a slight thinning of the nose.
The last bit of preparation work is to cut the fiberglass for the inbetween layer. This will be sandwiched between the XPS and EPS and will lap the bottom layer of the EPS.
Thanks so much for following along and we’ll move on to gluing up the core elements in the next post! Now we won’t be doing any resin infusion in this build but we will start to share our new pump/vacuum system.