I think your basement has kept you plenty busy! I wouldn't call you a slug.
I got the resin from a surf board supply store, made esp for boards. Says it's got UV stabilizers, whatever that means. I'm assuming this may be different stuff than regular, but we'll see. I also have an additive I'm supposed to add. All new to me.
Wow that's awesome! Thanks for taking us along although i'm not going to lie at the rate at which you and Chestnut knock out high quality projects makes me feel like quite the slug lol
One tip I'm sure you were planing on it but just in case you will need to coat the epoxy with a top coat as UV will break the epoxy down.
I've been playing hooky from my Hank Chair build. First I'm having trouble getting into that build, second I hand to order a few router bits, and thirdly I think I have ADD.
Well, while I was waiting on my order of router bits to arrive, I pulled down a framework I had made for a surfboard. I had put it together awhile back but the wood I planned to use for the project still needed some drying time. I milled 3 paulownia logs this past year specifically for this project. It dried real fast, but needed a few warm months to fully season. I milled it in Dec, and 2 weeks ago it was down to 12%. I started messing around with the frame and before I knew it I was knee deep into the build. And this build took up my whole shop, since it's a longboard, approx 10 ft. No room for the Hank chair. I thought this would be an interesting build to show, and even though I didn't take a ton of photos, here goes.
First, I've been doing a lot of research on building a board. There are a few techniques, all resulting in a hollow board to reduce weight. Wood needs to be light and paulownia fits the bill perfectly. For those who have never worked with this wood it is an absolute pleasure to work with. Tools easily, bends well, and is SUPER light. I was originally planning to do this build with my son, but he is living at the beach this summer where jobs are plentiful. I plan to do the build and we plan to glass and finish the board together down at the beach.
To start the build you create what they call the spar, it's basically a skeleton framework that the shell is attached to. I used 3/8" plywood for this. I bought a pattern for the spar. Printed it and glued it to the plywood, cut it out and shaped it. The skeleton was rather flimsy and did not have a lot of surface area to glue the deck boards to, so I supplemented the gluing surfaces with 3/8" paulownia strips. Here's what that looks like;
High spots were leveled off and then I started laminating the deck. Starting with the center board, I worked out to the edges. I used Titebond 3, this was the recommended glue. The decking was just under 3/8" thick stock, resawn from the 6/4 boards I milled. The info I researched said 3/8' for balsa and 1/4" for paulownia, I split the difference. Here's the top deck roughed out and glued on;
The plan calls for a relatively flat top deck and a curved underside. The curve on the underside is referred to as the rocker, here's the board ready for the underside, gluing up the last of the paulownia supplemental glue strips;
Here's the underside completed, walnut accent like the top;
From the side profile you can appreciate the curve of the rocker;
Now it's a matter of squaring up the sides and start gluing on strips to form the rails.
The rails are laminated pieces you glue to the sides that will be rounded off. I started with one solid strip and now I'm adding a decorative strip of walnut:
Adding these strips have made me appreciate the number of clamps I own;
The plan also calls for a fin, here's what I came up with;
Where I'm at now is I need to finish gluing up the rails, shape them, add the front and back pieces that will make up the front and tail of the board. Final shaping and sanding is last. Once at that step you need to glass the board, which is adding fiberglass sheets to the board, epoxy will be used for this step. After glassing you add the fin, that is epoxied and glassed on separately, and then the whole board is sealed with a layer of epoxy. This is completely new territory for me so doing it at the beach seems best as there are a bunch of surf shops around in case my son and I need help.
One other necessity with a hollow board it to install a vent. This is so if the board is sitting in the sun it won't heat up internally and start to delaminate or crack. I'm going to use a goretex vent that doubles as a leash attachment. I've glued a backer board on the inside for this and we'll install this after the glassing also.
Thanks for looking.