So ive been thinking and researching recently (not particularly seriously yet) about building a Carbon Fibre deck from scratch.
All the info I've been able to find online has been about surf/ skim boards with the foam core, which obviously isn't what i want.
Has anyone done one before that can shed some light, or can you direct me to somewhere online that has thorough instructions, that a relative novice
to these things could follow ?
Tagged...to follow this thread as well...
I've done minimal fiberglass work (patch jobs on surfboard) but would love to lay out my own CF deck...
Looks like most of the big dogs use vacuum bags and monster presses to do it with...
How about a "cheap" way to do up a CF deck??!!
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Yeah, ive done 1-2 minor things with fibre glass, but not carbon fibre.
All the stuff ive seen (with the foam core) essentially are very simple;
Layer the core with carbon fibre sheets, and the epoxy / hardener, stick in a vacuum bag. I guess one without a foam core would be very similar ?
I would love to do something like this, especially on the cheap
I'm still a sucker for all things home made, and like to have a project or two on the go
check kitecrowd. There have been a couple threads from others who have done so there. IIRC Plummet has made a few and seemed to know more than a
thing or two about it.
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I looked into doing this at school here at the AFA. We have Carbon Fibre you can buy for the price payed at large quantities, and even then, with all
the mold making, beta trials with Fibreglass and whatnot, it's still cheaper to buy a Pro 95 deck from MBS. Sad but true.
Really ?? I had a quick look for a pro 95 deck. theyre £220 new in the UK,i reckon i could do my own carbon deck for between £100-120. (im not sure
what that is in USD).
For anyone interested in some general CF instructions, check this out:
Actually, if you're interested in laminating an existing board with carbon fiber, you could vacuum bag this relatively easy without investing in the
effort to make the molds. Production parts are easy and cheap (minus material costs), but mold making is never easy or quick. If you have molds CNC
milled, then you're looking at several thousands of dollars (US) for machining costs.
Originally posted by joedy
Actually, if you're interested in laminating an existing board with carbon fiber, you could vacuum bag this relatively easy without investing in the
effort to make the molds. Production parts are easy and cheap (minus material costs), but mold making is never easy or quick. If you have molds CNC
milled, then you're looking at several thousands of dollars (US) for machining costs.
-joedy
Ahh, see id want to make one from scratch ! That's part of the fun for me. Although i totally get your point!
I have an idea for a mould that will take me no longer than an afternoon and not much more than £10 (15USD)
Production moulds tend to be more expensive because they need to stand up to repeated use, are often made of metal, and generally a single mold
actually presses multiple decks at a time.
"Shade tree" or "garage builds" generally use molds made of high density foam or wood laminates.
If you don't trust yourself with accurately cutting these materials, you can split the difference by modelling it yourself using a CAD program and
have it cut for you on a CNC machine for an additional cost:
I am not sure about the £100-120 estimate. You have to factor in core material, prepref CF, epoxy resin, mould material, vacuum bag, compressor,
breather material, and incidentals. If this is your first build, also add in a fudge factor for mistakes-trial/error. Unless you are sourcing
materials and equipment from a limited number or sources or predominantly local, there's also going to be shipping costs which can add up quickly.
It's probably still very doable... just don't kid yourself that it's going to be a wicked bargain. In the end, you'll end up with something unique
and the satisfaction of having built it yourself which is an intangible that might offset the coast.
Another good source is the Roarockit site. They are a Canadian company that teaches classes on how to build skateboard decks, sells kits and supplies a line of vaccum bags.
Their site is also chockfull of tutorials. Again, aimed at street decks, but the info is easily transferable to off-road and kite decks.
ATB,
Sam
"I never had any friends later on like the ones I had when I was 12 - Jesus, does anyone?" - The Body by Stephen King
Great, thanks for that info, Sam, I'll definitely check out those sites!
The more i hear about it, the less financially viable it sounds. But the more I want to do it
Someone on KC suggested using a core (the middle 50% of layers) of fibre glass. This apparently cuts costs, paying the price of increased weight. What
do you think ? Although it would make sense financially, I would want the board to be a genuinely good one, and i dont know if down the line i would
regret that move.. ?
We had a friend round recently that owns a boat yard close to me, he knows someone whos a real pro with carbon fibre, has massive workshops, and has
constructed amongst other things, a world class race catamaran, completely by hand from carbon fibre. Hes an eccentric apparently, but is happy to
help people out. So i may have to get in touch with him !
Originally posted by elfasa
We had a friend round recently that owns a boat yard close to me, he knows someone whos a real pro with carbon fibre, has massive workshops, and has
constructed amongst other things, a world class race catamaran, completely by hand from carbon fibre. Hes an eccentric apparently, but is happy to
help people out. So i may have to get in touch with him !
Originally posted by elfasa
The more i hear about it, the less financially viable it sounds. But the more I want to do it
Someone on KC suggested using a core (the middle 50% of layers) of fibre glass. This apparently cuts costs, paying the price of increased weight. What
do you think ? Although it would make sense financially, I would want the board to be a genuinely good one, and i dont know if down the line i would
regret that move.. ?
Tim
Unless you are weight compulisive because you have your eyes set on a team rider slot with a focus on freestyle, the weight difference is not going to
be monumental. Also there's nothing that says that this will be the only and only board you ever build with a "till death do us part" clause in the
ownership contract.
There are plenty of good boards out there that aren't 100% CF. To the best of my knowledge CKB were one of the few all CF boards, but they were a
tad crazy.... they even built some of their trucks from carbon fiber.
ATB,
Sam
"I never had any friends later on like the ones I had when I was 12 - Jesus, does anyone?" - The Body by Stephen King
I have personally built my own press out of concrete with no problem. My mold is based on an old atom 90 deck and I pressed 11 sheets of maple with
type III wood glue and its alot smoother deck for me than the Atom. I weight about 190 pounds and the board has plaenty of flex. Just an idea other
than the carbon fiber if its to expensive. The cost of one deck pressed is about 80 bucks once you build the mold and that maybe 5 sack of concrete.
Originally posted by indigo_wolf Unless you are weight compulisive because you have your eyes set on a team rider slot with a focus on freestyle, the weight difference is not
going to be monumental. Also there's nothing that says that this will be the only and only board you ever build with a "till death do us part" clause
in the ownership contract.
There are plenty of good boards out there that aren't 100% CF. To the best of my knowledge CKB were one of the few all CF boards, but they were a
tad crazy.... they even built some of their trucks from carbon fiber.
ATB,
Sam
You make, as always, a very good point. Thanks Sam ! I'll try and factor in using some fibre glass too, see how that effects things.
Cleeg05- you made a mould from concrete ? How did you manage that ? Ive got a few ideas on how you could have done it, but none work out..
Its pretty easy make you a mold box about two foot high and as wide as you board. Wrap your old deck in plastic to keep the water from the cement from
soaking into it. Get a sack of play sand and wet it in a bucket to the point where it is moldable. Lay enough sand in the bottom to fill in around the
board and under the board so its level then smooth the sand around the edges of the board so its level across the mold and follows the curvature of
the board. After you have it level mix you concrete in a bucket and slowloy add it to the mold over the board and sand repeat for both sides of the
board and it makes an upper and a lower mold then you make a block out of two by fours with a bar over the top to push against with two bottle jacks
and thats it.
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