I have wanted to try using foam for a while now. I have learned a great deal from the Fish and have seen many foam cores. I have always wondered, "is it possible to create a nice, stiff, light, foam core, without the use of expensive foams and carbon fiber?" This is the proposed question, and my answer.
The following is a DH deck, using only fiberglass, 1/8" BB, 1/2" poplar, and pink insulation foam, all relatively cheap stuff. The glass is about $6 for the two 45" skins, epoxy, a few bucks, 1/8" BB strip about 3-5 bucks, and foam is pennies as the pink 2 lb density stuff is 5-10 bucks for a 4' by 8' by 1/2" sheet.
Its pieces were cut and sanded, then vacced all in one step. It was hot-coated with epoxy only. No clear or polish in this proto puppy. I did try a veil layer of glass over the bottom to get a better finish, but it did more harm than good with trapped air, as you can probably see. The next will have less bubbling, hopefully.
Despite the lower quality foam, it is quite substantial, resisting squeezing and compression, especially coupled with the BB. It is also quite stiff, with only a slight flex. It is tremendously light at 1255 grams or 2.75 lbs without grip.
A few more to show. BTW, the cutout is a my drop through template modified for DH. It is right at 10" wide with a 32" WB. Fun to ride, easy to throw around.
Nice dude. Let us know how it holds up, I know especially with surfboards the pink foam has "degasing" issues. The foam will release gasses used to make it when it heats up, causing delam. In the future I'd recomend trying to "pre" de-gas it by poking some pinholes through it and leaving it in the sun for a while.
depending on what style of glass you used, but i think your scale is miss calibrated, spring style scales are notorious for being off, just basing this from very similar past builds ive done myself.
but what type of glass did you use and how many layers ?
you know what would be killer? pics of the building process. i'm very interested on how you did it...the way you said it made everything seem really easy
you know what would be killer? pics of the building process. i'm very interested on how you did it...the way you said it made everything seem really easy
luffty go to bed. It is way past your bed time mister.
OK. I didn't answer this originally because I am committed to only posting new and worthwhile information. The reality is, is that there are plenty of posts, depicting the creation of a foam core speed board like this. The basis is quite simple. From top to bottom, glass, wood ply, foam, glass. Others have done a much greater job than I. Look at all the posts by "wefunk" and you will find answers to your questions and more. He is back in action as well. I will post my discoveries and techniques to come, but only if it is worthwhile. The foam is crappy pink styrofoam from home depot and the glass is triax from Fibergalsssupply.
I have wanted to try using foam for a while now. I have learned a great deal from the Fish and have seen many foam cores. I have always wondered, "is it possible to create a nice, stiff, light, foam core, without the use of expensive foams and carbon fiber?" This is the proposed question, and my answer.
The following is a DH deck, using only fiberglass, 1/8" BB, 1/2" poplar, and pink insulation foam, all relatively cheap stuff. The glass is about $6 for the two 45" skins, epoxy, a few bucks, 1/8" BB strip about 3-5 bucks, and foam is pennies as the pink 2 lb density stuff is 5-10 bucks for a 4' by 8' by 1/2" sheet.
Its pieces were cut and sanded, then vacced all in one step. It was hot-coated with epoxy only. No clear or polish in this proto puppy. I did try a veil layer of glass over the bottom to get a better finish, but it did more harm than good with trapped air, as you can probably see. The next will have less bubbling, hopefully.
Despite the lower quality foam, it is quite substantial, resisting squeezing and compression, especially coupled with the BB. It is also quite stiff, with only a slight flex. It is tremendously light at 1255 grams or 2.75 lbs without grip.
Keep it up and you might be able to open up your own custom board shop
Nice work
Sorry, you live relatively (sort of) close to me, so I was wondering if you got the fiberglass from somewhere local. And I didn't ask about anything other then the fiberglass??????????
Sorry, you live relatively (sort of) close to me, so I was wondering if you got the fiberglass from somewhere local. And I didn't ask about anything other then the fiberglass??????????
No worries mate. I grew up in Charlotte. While back. There was a nice skate park on South Blvd. Gone now. Nowhere near to get this stuff that I know of.
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New deck, DH, foam composite, cheap stuff.
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Originally Posted by d-dub
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