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


Applying the epoxy filler
Once the shape was refined and as smooth as I could get it I applied a slurry of one part epoxy to one part 407 light weight filler to the entire surface.This step fills in the open cells of the foam and will help give the fiberglass a better surface to bond to.

I found some good articles on composites and lay up techniques at EAA which is the Experimental Aircraft Association. http://members.eaa.org/home/homebuilders/building/composite/articles.html

I applied the epoxy with a standard plastic epoxy spreader. You will have to do some sanding after it hardens to remove the high spots and ridges. You might also need to fill thin spots, dents and voids with a second coat. I probably added some unnecessary weight by trying to get it too perfect. The epoxy skin coat seems to add quite a bit of strength.







 

 

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