I don't think I've done this on TO.com, so I thought I would detail a full build rather than just bits and pieces. I am going to be building three prototypes to test the carbon on the stringers. I have finishe the first one with 1/16" stringers THIS build will be with 3/32" stringers and a final one with 1/8" stringers.
There are several types of foam suitable for surfboard construction, the two most common are polyurethane and Expanded Polystyrene or EPS the white beaded foam. XPS is Extruded Polystyrene - the pink and blue insulation at big box stores. Technically XPS is styrofoam (Dow chemical trade name), although most folks refer to the white beaded EPS as Styrofoam.
Polyurethane is a close cell foam, and won't take on water. EPS is manufactured with tiny beads that are fused together. Typically theses beas aren't well fused and so will allow water in between the cells. XPS is a closed cell foam also, but it is copolymorized with polyethelene which NOTHING sticks to...one of the big issues with XPS is delamination.
So for this project, I had a section of EPS left over and I am using that. EPS comes in various densities - typical is 1#, 1.5# and 2#. 3# is available but is more difficult to find. There are many grades of EPS the best is the c sizes (small) beads that are all virgin. However, the INSULFOAM stuff you can find at Home depot also works pretty well.
This piece I have came from FoamCarvings.com in Sacramento. A local insulation contractor most likely has large billets available also.
I will be building a perimeter stringer, but a center stringer can be made and quite frankly is much easier.
I start by aligning my finished shape on the EPS so that I know I have enough foam!!!!
Then drawing a centerline I place a template over the middle that I will use to mark the location of the stringer cuts.
In this picture you can see the masonite template, a sample board and the marked up EPS.
There are several types of foam suitable for surfboard construction, the two most common are polyurethane and Expanded Polystyrene or EPS the white beaded foam. XPS is Extruded Polystyrene - the pink and blue insulation at big box stores. Technically XPS is styrofoam (Dow chemical trade name), although most folks refer to the white beaded EPS as Styrofoam.
Polyurethane is a close cell foam, and won't take on water. EPS is manufactured with tiny beads that are fused together. Typically theses beas aren't well fused and so will allow water in between the cells. XPS is a closed cell foam also, but it is copolymorized with polyethelene which NOTHING sticks to...one of the big issues with XPS is delamination.
So for this project, I had a section of EPS left over and I am using that. EPS comes in various densities - typical is 1#, 1.5# and 2#. 3# is available but is more difficult to find. There are many grades of EPS the best is the c sizes (small) beads that are all virgin. However, the INSULFOAM stuff you can find at Home depot also works pretty well.
This piece I have came from FoamCarvings.com in Sacramento. A local insulation contractor most likely has large billets available also.
I will be building a perimeter stringer, but a center stringer can be made and quite frankly is much easier.
I start by aligning my finished shape on the EPS so that I know I have enough foam!!!!
Then drawing a centerline I place a template over the middle that I will use to mark the location of the stringer cuts.In this picture you can see the masonite template, a sample board and the marked up EPS.
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