Tooling, Pass Type and Production method for Composite Hydrofoil

[dachopper]

Do we think this will work?

I did a parallel finish job without any roughing, contact point with stepover 0.5mm, full depth contact cut, and cut the entire side, then flipped the piece, and did the same again, so once cut the foil has no support ( behind the tool path ), but immediately on the cutting face ( in front of the tool path ), it is supported full length for the entire length of cut? Then once it gets to the far end, I chop both ends off and the piece is complete? No vac table, no supports and no mould required? The only gotchya is that I have to finished the part with a single pass in each direction.

[Boyan Silyavski]

Before all that : http://www.surfersteve.com/smwavedesign.htm,

next question is - are you building an 1 off or a mold???

Anyway if i was doing it:

1. be 100% sure about design and final shape then make it from hard foam

2. When happy with the above , make a wood mold, 2 parts to be clamped

3. Then experiment clamping different stuff and playing with materials inside that shape untill i balance rigidity, weight and price

Thats it

[dachopper]

Cheers, we would use foam for ease of machining, but can't get any here, and it's $$ to import.
Making the bit under the water, not the board :)
https://youtu.be/hP4AcEQYi5w

[Boyan Silyavski]

Its a building insulation foam available anywhere?? for 120x60x4cm for example here in Spain for 4 euro at any construction shop. Up to 100mm thick. No super duper foam. this for the test shape pieces. can be glued together to form thicker pieces. Check local lettering companies. big letters for shops and restaurants are made from better variant of this foam.

[dachopper]

I live in a desert, they have no foam whatsoever anywhere and the Marine ply - or importing G10 is about my only options.

Anyone on here who has cut plywood care to comment?

[komatias]

I live in a desert, they have no foam whatsoever anywhere and the Marine ply - or importing G10 is about my only options.

Anyone on here who has cut plywood care to comment?

How about making your own foam using the expanding polyurethane stuff used to keep door frames in place while building?

[dachopper]

I have used that stuff when I made my first board, it's not rigid enough. The core needs to be rigid like solid wood plastic metal or composite