How to Build a Wind Foil Board - Part 1

[@chuckr3398]

For cutting the outline of your boards recommend you build a stationary work table vertical hotwire cutter! Then with outline template on the top of the board foam block and block laying flat and level on your table; simply push the block into the hotwire cutter and follow the template around. This will make nice vertical outline cut with minimal sanding needed to smooth out.

[@goldney]

Good idea, and would be a lot less mess, thanks!

[@ThomasDalum]

Quick question - how many watts does your power suply for the hot wire cutter?

[@goldney]

@@ThomasDalum If I remember, I set the power supply as high as it would go...2.4 amps, 24 volts, so 57.6 Watts? I used 26 gauge nichrome wire. It would have been better to be a bit hotter, as I had to drag it too slowly...you get a smoother cut if it's just hot enough that you don't have to pull it through with much force.

[@mikeflorence2336]

Great video. For us total beginners, where do you get the profiles and patterns for tour templates.

[@goldney]

This was only my second board, so I'm a beginner too! Board shape is as much an art as science...simple answer is copy bits from what others have done. But first, learn the basics of bottom shape outline and rail shape design and what effects they have. I tried to keep it simple...totally flat from footstraps back, with slight "V" up front with double concaves, small flat on sides.What I did was find boards I like, then try to copy certain aspects into the new board.

[@goldney]

I copied several pictures of boards into Google slides (use 1:1 scale makes it easier) made some minor adjustments then took lots of measurements to transfer to a wood template. Yes, Google slides! Illustrator, Inkscape etc would be better. Or use a board shaping program like Shape3D with option to send to CAD. Let me know if you want to see the file I used.

[@Dofarrill]

Where do you buy/order all your foam

[@goldney]

1lb density EPS foam: www.wesellfoam.com/ Divinycell H-80, 4' x 8' x 1/8" (cut to 2' x 4' to save on shipping): www.uscomposites.com/

[@Dofarrill]

@@goldney thank you !