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HWS Wakesurf Board
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Nooga678
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PostPosted: Nov 23, 2009 10:32 am    Post subject: HWS Wakesurf Board Reply with quote

I am making a Hollow Wood Wakesurf Board. I am making it as cheap as possible since this one is for learning. Hopefully, I will build a second one where I will put more effort into the looks. The frame is plywood, and to save money the top and bottom will be plywood as well. The second one will be made out of cedar. Since the boards are heavy compared to foam/fiberglass boards, it probably wouldn't function well as a high performance board. So I decided to make a 5'6" longboard for wakesurfing. Again not caring about performance I designed the profile based on looks rather than function. The rocker and width are simliar to industry boards of that length.


Here is where I am at:
Frame glued up. The foam in the background is an xps board I made to practice glassing.


Glueing up the bottom. Working on the ground sucks. If I decide to make more I will build a rocker table.


This will probably be a slow build, and I will update as things get done. I figured I would go ahead and start the thread.
The technique/how to/information can all be found at:
http://www.grainsurf.com/forum/
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beretta5spd
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PostPosted: Nov 24, 2009 7:11 am    Post subject: Reply with quote

looks really good. wakesurfing is one of the things I have never done. i will have to try some day
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dshaff24
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PostPosted: Nov 28, 2009 9:39 pm    Post subject: Reply with quote

Wow thats just awesome, Never would I ever thought of someone making there own wakesurf board! Can't wait to see the finished product
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Nooga678
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PostPosted: Dec 02, 2009 4:32 am    Post subject: Reply with quote

Got the chine strips glued on as well as some work on the nose. The chine strips ultimately determine the final shape.



I lost the screws that hold my router to its table so I am at a stand still until I buy them as well as a bunch of clamps and more glue.

Next will be to bead and cove the rail strips and start glueing them on. Once the first one is laid down I can cut out the final shape.
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Nooga678
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PostPosted: Dec 10, 2009 5:01 am    Post subject: Reply with quote

Got the first rail strips glued on. This allowed me to cut the bottom to shape using a trim bit in my router running along the first rail strip:

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dbismyname
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PostPosted: Dec 11, 2009 11:52 am    Post subject: Reply with quote

I love how you converted the volume into beers Laughing

I literally caught myself thinking, "when did I miss math class where they explained beer units?"
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Nooga678
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PostPosted: Dec 11, 2009 12:04 pm    Post subject: Reply with quote

LOL, I didn't notice that. The program must do it. I guess beers is some foreign unit of volume???

It has been pretty easy so far, but then again, I haven't been trying to make it look really good. AKU shaper is a free program where you can desing a board, then another guy created a free program that will take you board file and generate the stringer and ribs onto a pdf to build the HWS.

You will have to come down and ride the thing next summer. Maybe we can get Dillion out!
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dbismyname
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PostPosted: Dec 11, 2009 12:09 pm    Post subject: Reply with quote

For sure, I tried to get Dillon out all year I think he'd be a natural boarder. That fool has no fear bombin some crazy hills over by the country club on a long board. You get an open spot on the boat some weekend next year just let him know and I'll be down there in about 2 hrs.
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Nooga678
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PostPosted: Dec 14, 2009 4:33 am    Post subject: Reply with quote

Glueing up the rail strips:


Rails ready for sanding and shaping:
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Nooga678
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PostPosted: Jan 04, 2010 4:50 am    Post subject: Reply with quote

Got the deck glued on and rough cut to shape:


Apparently plywood doesn't like bending two different directions at one. I should have cut the plywood into strips.

Now comes a lot of sanding.
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NKCrider
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PostPosted: Jan 04, 2010 12:23 pm    Post subject: Reply with quote

let us know how she rides and i may built 1 in the summer Laughing
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Nooga678
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PostPosted: Jan 08, 2010 11:36 am    Post subject: Reply with quote

This is kinda of a weird design, but you could make one with a more typical design. In fact it is pretty easy to copy a board using AKU shaper if you know the parameters of the board you are copying. It seems the surf style wakeboards are getting thinner which doesn't lend itself to this building style.

It will be significantly heavier than a foam board so I look at them as more of for crusing. This one is long and wide, so as long as the shape doesn't screw with it, it will be good for people to learn on. People make them out of balsa as well which may be closer to foam weight, but the building method is slightly different.
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NKCrider
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PostPosted: Jan 08, 2010 11:40 am    Post subject: Reply with quote

yeah, i would go with balsa for weight. also mine would be more of a long board stlye for just cruising since my wake isnt big at all
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Nooga678
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PostPosted: Jan 08, 2010 11:51 am    Post subject: Reply with quote

Here is two good Balsa build projects for ideas:

http://www.grainsurf.com/forum/viewtopic.php?f=11&t=375&hilit=balsa&start=0

http://www.grainsurf.com/forum/viewtopic.php?f=11&t=1071&hilit=balsa&start=0

I definitely want to give one a shot with this method, but balsa isn't cheap.
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surfdad
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PostPosted: Jan 11, 2010 11:49 am    Post subject: Reply with quote

I'm loving the HWS nooga! I maybe inspired enough to try an HWS myself. I'm still a big fan of the compsand approach - balsa over 1# eps in the board I just finished in these pictures.
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Nooga678
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PostPosted: Jan 20, 2010 7:07 am    Post subject: Reply with quote

surfdad, Nice, no one would know it wasn't a HWS. How much did it weigh compared to your other build methods?

With the longboard about to the point on waiting for warmer weather to glass it, I started another board. I cut up all the needed wood this weekend and started glueing it up last night. It is a parallel profile board which can be made with minimal tools and board lenghts. Pics to follow soon.
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Nooga678
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PostPosted: Jan 21, 2010 5:19 am    Post subject: Reply with quote

The begining of the Parallel Profile:
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Nooga678
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PostPosted: Jan 22, 2010 4:47 am    Post subject: Reply with quote

Here are some pictures of the long board I deemed "Pappa Woody":





And progress has begun on the parallel profile board:
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dbismyname
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PostPosted: Jan 22, 2010 10:56 am    Post subject: Reply with quote

Looks awesome. Do you know your total weight yet? Looks like you could take it with you to the beach and hit the surf no problem.
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Nooga678
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PostPosted: Jan 22, 2010 11:38 am    Post subject: Reply with quote

No. It still needs glass, though with plywood skins I think I can get away with just glassing the rails and seal coating the rest. I will be heavy compared to foam boards though. Most HWS get close to foam board weight going with balsa construction. I hope to takle one of these, but balsa is expensive and I am still learning. The parallel profile will be heavier just based on how it is built. I hope to cut down on its weight going with some <1/4" cedar for the bottom and 1/8" plywood for the top. These definately aren't going to be high performance boards, but we will see how they surf. Most of us that surf on my buddies boat just get up and carve a little anyway. Pappa Woody will hopefully prove to be a good board for beginers.
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Nooga678
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PostPosted: Jan 25, 2010 11:41 am    Post subject: Reply with quote

One internal layer finished and the other about done:


This one is going on hold for a few weeks until I get back to the inlaws to run the two layers through a drum sander. It will ensure they glue together more perfectly. Until then maybe I will start a third board. Laughing
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dbismyname
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PostPosted: Jan 27, 2010 9:54 am    Post subject: Reply with quote

No such thing as havin too many projects goin at once right?
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NKCrider
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PostPosted: Jan 27, 2010 11:47 am    Post subject: Reply with quote

dbismyname, i wish i had a project to do im bored shitless
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Nooga678
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PostPosted: Feb 12, 2010 4:28 pm    Post subject: Reply with quote

Finally got around to some more work. Glued up the bottom and internal layers. Working on glueing the deck together then it will go on.

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Nooga678
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PostPosted: Feb 16, 2010 7:15 am    Post subject: Reply with quote

The bottom:
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Nooga678
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PostPosted: Feb 18, 2010 6:32 pm    Post subject: Reply with quote

More progress. Got the deck on and rough cut to shape. Now comes shaping the rails, then I will clean up the top and bottom.


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imshirazy
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PostPosted: Feb 21, 2010 10:41 am    Post subject: Reply with quote

im sure i dont know as much as you do, but that last pic seems pretty thick for the board no?
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Nooga678
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PostPosted: Feb 22, 2010 4:11 am    Post subject: Reply with quote

It is about 2" thick. Two 3/4" internal layers and the top and bottom skin are a little under 1/4". The parallel profile method creates flat decks rather than a dome. However it also keeps the same thickness for and aft, so the really thick nose makes it look even thicker. The dome in ocean surfboards is a way to add more volume and bouyancy which is more important in catching the wave. For wakesurfing bouyancy isn't needed which is why there are such thin skim style boards.

These are made more to mimick surf style, but this method produces its own style board. Even the surf style wakesurf boards seem to be getting pretty thin, but with wood you are limited since the top and bottom have to be thick enough to be strong, and still leave "hollow" in between.

More progress. I cleaned up the planshape and started shaping the top half of the rail:


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imshirazy
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PostPosted: Mar 20, 2010 3:36 pm    Post subject: Reply with quote

so...any updates?
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Nooga678
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PostPosted: Mar 22, 2010 3:07 am    Post subject: Reply with quote

Haven't worked on it since that last picture. I can't sand in the garage because it makes a mess and puts a coat of dust on everything. I did build a sanding stand to use outside. Now I am waiting for some nice weather and free time to match up.
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Nooga678
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PostPosted: Apr 14, 2010 3:12 am    Post subject: Reply with quote

Finally some more work:




Some final touch up sanding and it ready for the sealer coat of resin.
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taitrt
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PostPosted: Apr 14, 2010 5:54 am    Post subject: Reply with quote

So, this thing looks sweet, but what exactly is it for?

I can't imagine having a wood board would be favorable over a foam and fiberglass board, If it were me I'd stain the thing and hang it on the wall or something. Sexy work though.
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Nooga678
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PostPosted: Apr 14, 2010 11:24 am    Post subject: Reply with quote

It is for wakesurfing. I have never ridden a wood board, but many surfers love the feel of wood and how the hollow aspect connects them to the wave. Wood is a completely acceptable material to use. Foam typically only out performs in weight. Most people I know just enjoy riding, trying a few tricks here and there, in which case a heavier board isn't going to matter that much. If you are pushing the limits of air of the lip then stick with the lighest foamy you can find otherwise why not ride in style. Cool
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Nooga678
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PostPosted: Apr 25, 2010 1:06 pm    Post subject: Reply with quote

More progress. First coat of resin on the deck. Fins and boxes are delivered from 4wfs and ready to be installed after all the resin.
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Nooga678
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PostPosted: Apr 29, 2010 5:11 pm    Post subject: Reply with quote

A couple of resin coats on the bottom:
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