As discussed in the FlyBoy Wakesurf Board construction article I mentioned that the FlyBoy Wakesurf board uses vacuum bagging techniques to build the lightest, strongest wakesurf board possible.
The vacuum bagging techniques consist primarily of a vacuum bag and vacuum press.
Think of the vacuum bag as a giant sandwich “Zip Lock” bag where the air is removed by a vacuum source such as an electric vacuum pump. When set up correctly, this creates approximately 1700 lbs per square foot of evenly distributed pressure inside the vacuum bag.
The vacuum press is the device that removes the air from within the vacuum bag. For wakesurf board building an auto-cycling vacuum pump runs automatically by measuring the vacuum pressure level inside the system and turning on or off as required to maintain a given level of vacuum. In building the FlyBoy Wakesurf Boards, the vacuum is applied while the epoxy is curing, creating the com posite sandwich structure.
Some of the benefits of using vacuum and why FlyBoy Wakesurf uses it exclusively in the fabrication of wakesurf boards:
1) Better uniformity of lay up – No thick / thin cross sections as is common with hand lay up
2) Stronger finished product – Higher glass to resin ratio than a hand lay up
3) Better Strength to weight ratio – best ratio of glass to resin
4) Smaller cross sections – A thinner cross section of a vacuum bagged lay up is stronger and lighter than a resin rich hand lay up.
Also, when used with a porous substrate made of peel-ply and breather-cloth, as I’ll discuss in a subsequent article, it assists in having the optimal ratio of resin to reinforcement (e.g fiberglass, or carbon fiber, or Kevlar) by squeezing out the excess resin.
The end result, for the rider, is a board that is strong, light and responsive.
63 comments
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June 9, 2010 at 5:33 am (UTC -7) Link to this comment
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June 24, 2010 at 10:59 am (UTC -7) Link to this comment
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June 30, 2010 at 8:07 pm (UTC -7) Link to this comment
You write very detailed,Pay tribute to you.Couldn’t be written any better. Reading this post reminds me of my old room mate! He always kept talking about this. I will forward this article to him. Pretty sure he will have a good read. Thanks for sharing!
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Mark Fettig
August 30, 2010 at 7:53 am (UTC -7) Link to this comment
has anyone tested the heat-shrinking films vs the vacuum bagging? The first step is to shrink the plastic, which provides the original airtight seal, and then the vacuum is added. As the composite reacts, the heat continues to shrink the wrap, which only compresses after the material has begun to harden
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August 30, 2010 at 9:19 am (UTC -7) Link to this comment
Yeah – the model rocket guys use this stuff for making fuselage tubes. It’s a little tough to wrap a board with it, but is does great for lapping the rails – like on a molded board where the lap is done again after the board is pulled out. Some fiberglass tape running nose to tail on the rail and, with some release ply on the outside, then the heat shrink film around the outside of all that. Hit it with heat and that lap is perfect.
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