How to Build a Hydrofoil: Fuselage - Final Shaping & Sanding (Video 13/15)

An in-depth video series for how to build a hydrofoil from home that actually works. There are several ways to build a hydrofoil, this is simply how I like to do it. - Free Hydrofoil plans here: flukeskitesurfing.com/hydrofo...
- Find Recommended Hydrofoil parts here: flukeskitesurfing.com/store/c...
- New videos posted daily @FlukesKitesurfing
In this video: Final shaping and sanding of the fuselage, we will complete the Hydrofoil Fuselage. Now that we have completed the rough shaping and tapped the M6 threads, we can finish the fuselage off by first using a trimmer router, rounding the sharp edges of the aluminium. Before routing, it's a good idea to mark the position of where the fuselage intersects with the hydrofoil wings, that way we don’t round the corners too far past the foil wing and ensure we maintain a sharp square edge for the wing connection points.
Once routed, we can countersink the screw heads for the mast connection. We countersink on the underside of the fuselage just for the head of the screw that will attach the mast. The screw head should be finished flush with the aluminium surface. Also, a small burr removing the “countersink” on all other holes is a good idea. This will let the screws find their place more easily when connecting the wings. To do so, just “countersink” a very small amount (1mm) on all other holes, top and bottom.
Now to finish the fuse off, it's time for the final sand.
Starting with a random orbital sander and 120 grit you can sand all of the alloy to smooth any imperfections and soften the rounded edges. Then we finish the fuselage off by sanding lengthways with the grain of the aluminium to a finish of 320-400 wet and dry sandpaper (sanding dry)
This is the finished surface of the fuselage.
Finally, You can also put some oil on a rag and rub it down to help protect the aluminium from corrosion. (It's a good idea to oil occasionally)
How to Build a Hydrofoil: Fuselage - Final Shaping & Sanding (Video 13/15)
0:00 Introduction
0:11 How to Build a Hydrofoil Fuselage PART 13: FINISHING THE FUSELAGE
2:45 Fuselage Routing MARKING OUT
5:07 Tip: Router Depth SET DEPTH SLIGHTLY LESS THAN FULL CUT
9:30 Tip: SPRAY FUSELAGE WITH WD40 BEFORE ROUTING
11:35 Countersink COUNTERSINK THE MAST HOLES + MIN ON SCREW HOLES
14:54 Fuselage FINAL SANDING: RANDOM ORBITAL 120 GRIT
16:53 Fuselage FINAL SANDING: HAND SAND 120-320
Can you make your own hydrofoil?
In my opinion, this is one of the best ways to make a hydrofoil from home. By design, the foil construction helps remove critical mistakes that people can make, leaving them with a hydrofoil that won't fly. The free hydrofoil plans are there to help you end up with a hydrofoil that works! So, If you're wondering if you can build a hydrofoil yourself DIY? You can!
How to make a hydrofoil playlist here:
VIDEO LIST:
1. How to Build a Hydrofoil: Planning and Design Principals (Part 1)
• How to Build a Hydrofo...
2. How to build a Hydrofoil: Machine and cutting outline (Part 2) • How to build a Hydrofo...
3. How to Build a Hydrofoil: Shaping the foil wings (Part 3)
• How to Build a Hydrofo...
4. How to Build a Hydrofoil: Resin Sealer coat (Part 4)
• How to Build a Hydrofo...
5. How to build a hydrofoil: Glassing the bottom (Part 5)
• How to build a hydrofo...
6. How to build a Hydrofoil: Holes and edge Resin filling (Part 6)
• How to build a Hydrofo...
7. How to Build a Hydrofoil: Top Fibreglass Lamination (Part 7)
• How to Build a Hydrofo...
8. How to Build a Hydrofoil: Resin "Hot Coat" (Part 8)
• How to Build a Hydrofo...
9. How to Build a Hydrofoil: Screw Holes & Final Sanding (Part 9)
• How to Build a Hydrofo...
10. How to Build a Hydrofoil Fuselage: - Planning & Drilling Holes (Part 10)
• How to Build a Hydrofo...
11. How to Build a Hydrofoil: Fuselage - Shaping (Part 11)
• How to Build a Hydrofo...
12. How to Build a Hydrofoil: Fuselage - Tapping Holes (Part 12)
• How to Build a Hydrofo...
13. How to Build a Hydrofoil: Fuselage - Routing (Part 13)
• How to Build a Hydrofo...
14. How to Build a Hydrofoil: Assembly and Final Points. (Part 14)
• How to Build a Hydrofo...
15. How to Build a Hydrofoil: The Test - Riding The Foil For The First Time. (Part 15)
• How to Build a Hydrofo...
Website Link: flukeskitesurfing.com/
Shoutout to Ryan parsons for helping test! / ryanparsonsofficial
flukeskitesurfing.com/

[@jamesmckenzie4572]

Looks great. I think I'll have a go at it over the winter. Nice to watch someone else cut aluminum with woodworking tools first. Thanks.

[@FlukesKitesurfing]

Yeah keep us updated with the progress! Another commenter mentioned a great idea.. to cut the alloy in increments, slowly raising the blade and do multiple passes. That is actually how it should be done more safely as you can see in my video driving through 1" is a lot for the saw.

[@davidharraway8131]

Cheers for these Luke. Really enjoying the process and you are a great teacher.

[@FlukesKitesurfing]

Awesome thanks David! Glad you have enjoyed it mate!

[@dijkx1]

Great detailed series. Keep up the good work. Your videos deserve more views.

[@FlukesKitesurfing]

Thanks mate! Glad it helped!

[@jesephgastallo7006]

It will be alright

[@FlukesKitesurfing]

Perfect