Surfing Waves

Hello. First post. Not sure if this is a good spot for this one. But here goes.

So I am obsessed with building a carbon fiber hollow board. First off I have 0 experience building surf boards, I know right, but I am experienced in the realm of carbon fiber, as a helecopter mechanic, so I can get supplies cheap, and I want to go big or go home. I have an idea of how I can do it. Trying to get any feedback if possible. Before you slam me, if your thinking about it. I would just appriciate constructive criticism. I am aware of the utter frustration when It comes to carbon fiber. And I understand that creating boards takes mad skill. But any way. Here goes

So I know Aviso and most other professionals that make the CF boards have two molds. They vacuum bag a top half and a bottom. Then the shells are sealed together. I was thinking (basic summary w/ several details and hurdles skipped over) if a styrofoam blank, could get shaped. Most likely the most expensive step because I would have to get a pro to do it. And I know that stuff has to be tough to shape and work with. But there is a reason it has to be styrofoam. Then lay some epoxy resin over it so the polyester resin doesn't melt it all away. Kind of like a sealant. Then, lay carbon fiber over that like you would glass a regular fiber glass surf board. Mark the fins. Lay the bottom of the board, w/ the lap and everything done up real nice. Install the fin plates. Do all the sanding and the gloss. Honestly I don't even know if I would gloss it. Just wet sand it. Install the leash plate. Then drill out the plug that is on the back. This is where it gets interesting. Am I'm not quiet sure it will work. Acetone will melt all the styrofoam and not the carbon fiber. If I pour it in where the plug is. Swish it all around and get the styrofoam all melted away. Then just pour it out and air it out. Bam. DIY carbon fiber board. It would leave behind a thin layer of the styrofoam that had the epoxy resin had impregnated it. But it SHOULD melt away most of the styrofoam. Leaving the board light. I am not sure of several things. Like how many plies of fabric to use. Exactly how the fins have to be done up so they are sturdy and sound. But that's the just of it.

I know it would be very slow going and monotonous. Lots of sanding. And probably a few redos. But I think
It would be fun. And pretty cool. What do you think.

I know nothing of carbon fiber boards, I have a couple boards with carbon fiber reinforced areas. What is going to hold the fins/finbox in place?

I figured I could glass the box into the carbon fiber. Before it dries. I'll have to do some research to make sure they will be strong enough.

how much 'float' would the board have - what is keeping it from sinking? In a normal board, its the foam core that provides bouyancy - if you just have a carbon fibre shell, would that float (once you add your bodyweight to it)?

Yea cause it is sealed. So it's air tight. Very bouyant. These boards are very popular/expensive

Ok, that makes sense.

Is it too bouyant? Boards need a bit of weight. But I've got no idea about carbon fibre (other than in yachts) so ignore me.

Not to dismiss our resident experts on this forum, but you should give your question a go on a forum called 'swaylocks', which is a forum for making surfboards. There are some guys there that can probably help you out.

Ah thanks man yea I'll put it on that one. I figured this wasn't the right one. It's my first post

The technique you want to use is called the lost foam method, and I believe you'll find information on it if you google 'lost foam'.

I'm not sure it would be worth the effort since the foam is very light anyway. Plus, you could have problems with expansion and contraction in cold/hot weather with the air inside the board. Salomen S-core boards used a screw in plug in the board which you remove when you're not surfing for this reason.

As you mention, the fin plugs would be a challenge, and you could end up making the board tail heavy with the necessary glass work to support the fins.

Another idea.

Knocking around on the ol' interweb area bunch of plans for hollow wooden boards that are constructed in a similar fashion to ships. Internal wooden spars for strength and rigidity then laminated with strips of wood.

Now, this is going to be very labour intensive, but it will probably work. You would use the plans to make mock ups of the spars which you can then use to make moulds with which to shape spars out of Carbon Fibre. Once you have all of those made and put together then (I could be very wrong here) isn't then fairly simple to just cover the board in carbon fibre sheet as you would glass over a regular board? This would also allow you to install fin boxes as the spars would give you something to attach them to.

Just an idea from a novice.

Yea I'm not sure. I was thinking of ribs with spars for a longboard made out of carbon fiber. I hear they break a lot. But I think it's going to be easier to make a split mold and lay two halves. Then laminate them together

Yea I'm not sure. I was thinking of ribs with spars for a longboard made out of carbon fiber. I hear they break a lot. But I think it's going to be easier to make a split mold and lay two halves. Then laminate them together