This is a continuation of parts 1,
2,
3&
4 Once the shell was moulded, adding the foam was next. It's a 2 part mixture that once mixed, you have about 30 seconds to mix and pour. Once poured it rapidly foams up, so I made a cardboard dam to kind of hold it in place and keep it from running all over the place as it went off. The foam is the same stuff that conventional surfboards are made of, polyurethane.
A lot of shaping later- mostly with a handgrinder and sandpaper, the board really takes shape.
Then the board got layed up with heavy uni-directional fiberglass, the strength was mostly needed in the nose to tail direction. Instead of building up layer and layer of normal 6oz, 20oz uni was used.
Here's the fin, made of an old Noserider fin. Rad
The board completed and sanded. Note the base on the fin. Made for easy mounting though the deck with a couple bolts.
Front view.
9 lbs total at the end, with hardly any foam in it. The first time I threw it in the water it sank so that it sat vertical in the water and just the tip of the nose was floating above the surface. Shocker. -Carl
