Initial Planning
The concept behind the construction of my iceflyer is to carve a foam core to the desired shape and cover it with fiberglass cloth and epoxy. Easier said than done:) All other dimensions are taken directly from the plans provided by IceFlyer. http://www.iceflyer.com

I used the Microsoft word templates from iceflyer and modified them referencing photos of the fiberglass version to get the shape I wanted. I created a full size computer file with the new profile and tiled it out on my inkjet printer to create two wood templates.Then I placed the wood templates on each side of a foam block and carved the profile using a hot wire cutter. More on that later.

You can download the template I created here. It is an .eps file. iceflyer_template_woodward.zip (171kb)

Materials

Foam Core
I used polystyrene foam (pink foam from home depot) glued together to create a large block of foam that was 16" x 24" x 96". A 2" x 48" x 96" sheet of pink polystyrene house foam is perfect because it carves well and is pre-scored to be broken into three 16" panels for use between wall studs. You will need 4 sheets to get the 24" width. I glued the foam together using 3M foam insulation glue.

Fiberglass
I'm using 6 oz plain weave S-glass. S-glasses are industry standard for sailboard fabrication. Also used on high performance surfboards for added durability. When compared to E-glass, S-2 laminates show significant improvements in tensile strength, flexural strength, flexural modulus and compressive strength. S-2 Glass Laminates also exhibit improved impact resistance and toughness. I bought my S-glass from these guys. http://www.raka.com/fibergla.htm. Lighter, stiffer and stronger.

Epoxy
I'm using the West System epoxy system. http://www.westsystem.com

Fillers
I'm using West System fillers for faring and filling. I bought West System 404 high density filler for creating hard points that will receive bolts and screws for hardware. I'm using West System 407 and 410 light weight fillers for fairing and filling the cells of the foam before laying the first layers of fiberglass.

Aluminum
For general parts fabrication. Working on a good source for this.

Steel
Looking for 440c Stainless Steel for the runners. Working on a good source for this.

Wood
Not sure what wood I'll use for the springboard and plank yet. Will keep you posted.

Hardware
I' m planning on using Harken hardware and blocks. So far the best prices I have been able to find are here. http://www.pyacht.com