Home
Planning and Materials
Cost
Hot Wire Foam Cutter
Cutting the foam
Refining the shape
Applying the epoxy filler
Springboard tunnel
Hard points and reinforcements
  Seatbelt attach point
Plank rope assembly attach point
Mast base attach point
Sheave attach point
Applying Fiberglass
 

Bottom
Top
Filler and Fairing

Hardware
Plank Attach Plates
Pedals System
 

Pedal Slots
Steering Linkage
Pedal Parts
Finished Pedal Assembly

Front Springboard
Rear Plank
Runners
Paint
Final Assembly
Photo Gallery
Impressions


Carving Foam
First I screwed the wood templates onto each side of my block of foam making sure they were aligned and square with each other using a level. Then I used the hot wire and followed the templates to create the rough profile that I wanted. (sorry I didn't take any pictures of the foam block but you can see the results after the foam was cut with the wire.



Hardboard templates used on each side of the foam block.



Side profile


Then I used a Stanley Surform rasp and a Surform Plane to slowly start carving. The seams in the foam act as a good guide as you work. You can use them like grid paper and double check that it is symmetrical.


Starting to carve out the seat




The boat is a little longer than the eight foot sheets of foam so I used the hot wire to create a section for the nose. It gets glued on later.



Still in rough form. What a mess.





 

 

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