Underoath said..
Found a bloke on the Goldy.
A blanks $80, and getting the board machined in $30.
Also Downloaded AKU.
Mate, my two cents worth-
These guys have everything you need to shape and glass a board on the sunshine coast-
acefibreglass.com.au/accessories/I have made a few surfboards in my time and agree with many of the posts here but to re-iterate:
Dont go for crazy channels or crazy combinations of concaves on your first couple of attempts, the screw up rate is high and youll be pissed if youve wasted the blank. Flat boards are heaps easier and faaaassstt! If anything, a single concave from the top third through to the tail works good and is fairly simple to do (I custom made a curved sanding block for this purpose).
Buy a close tolerant blank close to the size of board you want, the toughest part of the foam (specially the deck) is the crusty coating on the uncarved blank, use minimal planing on the deck, if anything just a light sand for shaping the deck will do.
I did my first couple of boards hand sanding only with sureform, sandpaper and sanding mesh, this stuff rocks, it doesn't clog and is awesome for shaping rails.....
www.bunnings.com.au/rocket-plasterboard-sanding-mesh-4-pack_p1661400The electric planer takes a bit of getting used to and you can take off a bit too much foam and its hard at first to keep the form, and the lines flowing, shapers make it look easy but they plane (or used to!) every day......I made a mistake on one board by taking too much foam off the deck and it was heel dent city after 2 surfs, and that was glassing with epoxy!
Glassing- start with Polyester resin rather than epoxy, reasons?
Polyester is heaps less sensitive than epoxy, the flow rate (it's thinner) is better meaning you'll get less bubbles.
Polyester is cheaper and a bit less sensitive to catalyst measurement (no excuse though, still be as accurate as you can with your mix, catalyst should be around 1%).
Its easier to work with all round and more predictable, you get gel time (eg some warning) before it goes off completely.
With epoxy when it goes off it does not gel, just solidifies all at once like hard plastic, one minute liquid, then next plastic.
Advantage is you get longer wetting time, but when it goes it goes......thats why its so good for vacuum bagging technique.
Temperature needs to be perfect.
Epoxy measurements need to be spot on, its not very tolerent to guesswork on the mix, it is not as nice to laminate with by hand, its stiffer and not as flowy.
The strength increase is negligable, is much stronger with an EPS blank, vacuum bagged with a fancy combination laminate (like a kiteboard or windsurf) but with a PU blank it's barely noticable.
Spend some time first making a good shaping rack, strong wooden yoke set into big concrete buckets, needs to be level, non moveable. Good base for accurate shaping.
Anyhow Ive waffled on too much now, I love the subject!
Two videos you may find useful (they are a bit old now but the info is invaluable), watch it over and over and memorise. Shaping 101 and Glassing 101 by John Carper
www.shapers.com.au/shaping-101/Enjoy!!