Building a Carbon Hydrofoil Mast V1

Building a Carbon Hydrofoil Mast - Pressure Molded

[@AntiVaganza]

Apart from the potential copyright and moral implications of copying a mast, no matter where you are in the world you should be able to get some Mcguirs wax (or similar) and possibly even a bit of PVA release agent affordably. The wax is likely easy enough and if you find a fiberglass boat builder in the vicinity, perhaps you can get a bit of PVA from them. With that, you would have the old school composite industry standard for mold releasing and wouldn't need to deal with the creases from the cling wrap. Anyhow, cool content and I really enjoyed your dinghy build.

[@sc0or]

) Your videos gave me one main idea: I need a 3d printer.

[@d4rkgosu798]

Amazing video man . Nice one👏👏👏

[@Jeff_Rowley]

Gloves. Safety first🤙

[@philiptuahu2466]

it's great and seriously builded

[@jamesmorton7881]

Smart guy. ❤❤

[@aimsy3508]

Hi ! I would like to gluing my plate to the mast with epoxy stick call Adrilite 2031 -1 , what do you think about it ? Thank for your understanding!

[@user-li6gp1ih7x]

Cool! Thank you!

[@miguelange3778]

Hi...magnificent video, you are paving the way for many people..question what is your resin for making the counter mold..?

[@HANDIY]

Thanks, for the mold i used a cheap epoxy mixed with Q-cell.

[@fedemon76]

Hello very good video! One question. In your opionion is possible with this method to copy an already existent aeroplane (the down part of the hydrofoil)? Suggetsion?

[@Janpva.]

okay yes.. this is impressive.. but can't you just make it in carved Multi plywood ?

[@HANDIY]

thanks, yes indeed you can.

[@Janpva.]

@@HANDIY yeeeah cool, thank you for telling me what I wanted to hear

[@grokuikforest]

Well Done great job! do you have the dimnenssions of the mast ?

[@mustaphaben2921]

Electric foil should be the same but with cables (power for the motor)?

[@ymcordier1]

No gloves ?

[@surfguy4u]

Is the carbon layup dry when you add the foam or wet too bond to foam?

[@HANDIY]

The carbon is saturated with epoxy before pouring the foam.

[@teaganr3512]

About how much epoxy did you use

[@commanderkeeno5552]

Hi, cool video. I’ve been doing all sorts of composite parts over the years but this is a method I’ve not seen done. Do you think the method will work just as well for moulding and making surfboard fins?

[@HANDIY]

Fin shapes are a little more complex, the inside layup might be a little trickier but theoretically i think it could work. The fin Tabs might be the toughest part to figure out. Its hard to find info on how real manufacturers do it, I imagine its a similar process.

[@surfguy4u]

Is epoxy dry before foam is added??

[@HANDIY]

no its still wet

[@sirpapstv]

Can I buy from you... How much will it cost me...

[@weganan]

What did you use to mix with the epoxy to create the white mixture for on the wood in the mold?

[@HANDIY]

Q-cell

[@bartheijboer881]

Nice example, I am going to make a simular mould including the base for a powerbox and fualage for my current windfoil hydrofoil . What gr carbon material have you used in this mast? And is this buid layout rigid enough?

[@HANDIY]

Carbon is 11oz 3 inch unidirectional, the mast does flex a little, I will add a little more next time. Also for diagonal layers, it would probably work better with Bi directional carbon. Cheers

[@luclareau3949]

to have already made two masts for the windfoil and wingfoil I advise to put many more layers of carbon for the mast and also between the base and the mast

[@ChristianNally]

Thanks for posting! What holds the two halves together? (Do the carbon layers adhere to the foam?) (Is there a risk that it would split in two top to bottom?)

[@HANDIY]

Good question, it seems several factors contribute to the mast's structural integrity. The epoxy inside the mold is pushed towards the leading and trailing edges, effectively gluing the two halves together. Also, the foam used is highly adhesive and bonds well with the epoxy. The top and bottom sections of the mast are made of solid epoxy/carbon fiber, providing additional strength. While there is a risk of the mast splitting in the middle, I've conducted tests by putting my weight on it, and it does not seem close to its breaking point. I've had many successful sessions with it so far. I'm still experimenting with different carbon layups inside the mold. Cheers!

[@ChristianNally]

@@HANDIY Thanks! I also imagine that the force pushing the sides of the mast apart aren't that high. (Maybe just fly faster so they get sucked apart? ;-) ).

[@noomapollo5389]

@@HANDIY I thought you might add a layer of carbon to leading edge and trailing edge after molding. But apparently the foam is enough to hold the halves together. Nicely done!

[@rolfnilsen6385]

Did you use some sort of barrier cream to protect your skin from the epoxy while working with wet epoxy? It was a very interesting video! I suppose the loads are not crazy if the mast holds up with no shear loading failures 🙂 I'll have to binge through the rest of your build videos. I have some F18/F16 catamaran daggers and rudders to build and your videos are inspirational.

[@HANDIY]

I should have used gloves for sure. The mast still works well, surprisingly no shear stress issues but does twist easy. I recommend checking the Mast v3 construction video for a better overall construction by doubling diagonal carbon layers, extracting PU and replacing it with high density Filler. Best of luck with you builds, i imagine you could use a similar process but you'll probably want to add fiberglass or carbon at the seams just to be safe.

[@kitejake]

Great job! Looks like 90-100 cm? How is the flex?

[@jamesstewart5371]

HANDIY greetings from Cabarete is that a monofoil at the end of your video?

[@HANDIY]

it is indeed :)