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kellsmith
Miki Dora status
Reged: 04/18/11
Posts: 3840
Loc: South Bay
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a build thread - recycling project
04/05/12 10:44 PM
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i always enjoy threads like this so now that i can contribute one of my own, just finished it today… here it is, from the beginning, all at once.
this is the second board ive shaped (first sucked) but the first time ive done any other steps. im a total rookie.
the whole thing was a big learning experience. apart from tons of searches on swaylocks i was pretty much on my own.
started with an old 9'0 becker longboard. 1 stringer, 2 glue lines outboard. piece of crap, yellow and waterlogged and gross. for free from my friend.
stripped the glass, cut off the unusable parts. a ton of foam on the deck was rotted/waterlogged and the stringer was too. i put it on my roof to dry but the next day it started to rain and i wasn't home to take it off the roof… idiot. so i put it in the rafters to dry out for a few weeks.
here it is templated, template taken off a 70s lis.
i had to take a lot of foam off the deck due to the poor condition of the blank. used a shitty power planer for this. didn't have calipers and was worried about ending up too thin… outline cut and bottom roughed out. went for belly - flat - vee.
working on deck and rails. did rail bands with sanding block +120 grit. not the easiest but it worked. my "shaping stands" are pretty janky
shape is done, fins marked, ready for lam.
lam sched: 4 + 4 x 4, all s cloth, and RR epoxy resin w/ orange tint. strong.
my crappy shaping stands turned "glassing stands". used the boxes so the board would get up off the wide arms of the sawhorses. tarp on the floor. ha ha.
bottom lammed. it was pretty stressful, first time ever lamming a board. was listening to tool (album: salival) and it stressed me out even more. not relaxing! laps were tough, i was bumbling my way thru it. luckily the epoxy has a long working time and just slowly gets more and more gooey. could not have done this without epoxy! or maybe uv cure poly…
shitty cutlap.
top lammed. this time i listened to van morrisons astral weeks and it went a lot better  ..
made my ultra trendy label in a free program called inkscape.
made the mistake of using brown tracing paper for my logo lams. no rice paper. didn't soak much resin and it cured kinda weird under the cloth. oh well..
here are my fin panels. 22 layers of 7.5 oz volan and another smaller panel of 18 layers. i tried to inlay paper (words) into the layup but it didn't work. dumb mistake, used vellum paper, completely de lammed while i was cutting the fins out. the paper was only 2 layers down though so i didn't lose too much thickness.
here i am cleaning up the inside curve. i was proud of my little set up to hit the inside curve. dremel clamped to act like a spindle sander. its the little things….
more improvisation, fin foiling station. was pretty itchy after this
foiled with 4.5 inch angle grinder. like butta. mains are rocket fish template tweaked slightly. canards are based off bonzer runners
fins tacked on with hot glue. that is my cant template, 5 and 22 degrees (more bonzer influence). thanks to twinzerfan for some help with the placement numbers 
about to glass em on! nervous at this point cuz i have no idea what im doing. had another try at inlaying my text into the fins. used rice paper this time. worked great.
tried to trim the excess later that night. i decided to abandon that because i felt like i was delamming the job i just did and it wasn't cured enough. it was late and i went to bed. bad idea.
next day, everything was rock hard. what a bitch! didn't realize it would be hard to find the true fin template with all that excess cloth. it was hard.
hours of sanding later, i was satisfied. stoked at this point cuz it looks like a real board.
read lots of horror stories about fisheyes in epoxy hotcoats. paranoid so i prepped really well. sanded 120 immediately prior to hotcoat. went well, only 1 weird spot which i filled. did the same on the top and it was ready for sanding round 1.
wayne oak was nice enough to offer one of his rooms (as well as one of his milwaukee sanders) for me to sand in. as soon as i hit the hotcoat for the first time i realized how bumpy my lam and hotcoat was. ha ha again.
sanded round 1.
around this time, i made myself some real stands. super solid, 4x4 and 2x4 set into two 60lb buckets of cement. stained the wood , stapled on some padding and i like em a lot. they don't budge at all plus the padding is a certain texture that the board doesn't slide on em either.
lots of weave showing, hotcoat 2 necessary. did some pinlines first. the one on the deck came out lame. did it "cheater" style with 1/8" masking tape to space it. too thick. ditched the crutch on the bottom and got a little more creative. came out way cooler. i was more careless with this hotcoat and got some fisheyes but filled them and all is well.
sanding round 2 at waynes again. lots and lots of sanding…. sanding around and on the fins was pretty damn tough.
and then its done! came out pretty good for my first build, at least i think so. im stoked! stringer says 5'6 20.5 2.5 buts its not exact…
note the pinline difference...
the fins are lyrics from a rage against the machine song, "know your enemy"
they say "compromise conformity assimilation submission greed ignorance hypocrisy brutality the elite all of which are american dreams"
overall, im most proud of laying up/cutting/foiling/glassing the volan fins and the inlaid text
everything came out pretty far from perfect, to be certain.
its waxed up n ready to go! riding it in the morning, hopefully first impression ride report to follow. if it goes fast and banks turns i will be stoked  hopefully the first of many
 
--------------------
The glide shall not be truncated 
- roy
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