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Making carbon foil surf wings

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Created by wicka 1 month ago, 26 Mar 2020
wicka
VIC, 5 posts
26 Mar 2020 6:33PM
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Hey guys just looking for some tips from people that have had a go at making their own carbon wings. With all that's happening with corona virus I've been waiting for months to get my hands on an axis 101 but once we all go into lockdown it might be worth having a go at making a couple of wings at home to pass the time.
What sort of cores are the new high aspect wings? Are they wood? Or still foam?
any tips would be great. Cheers.

Gorgo
VIC, 4360 posts
27 Mar 2020 3:05PM
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I've seen a few homemade ply foil wings. They work fine.
Just guessing, but they're probably heavier, more fragile, and less refined than a commercial job. My mate's one worked ok while he used it.

surfcowboy
39 posts
27 Mar 2020 1:17PM
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I've built a wing out of eps, hand shaped. Check out my aquarium pump vacuum pump over on the zone.

You can 100% do this. Results may vary, But they are cheap and you can make a few and see how they work.

Plywood is a great way to start. The real guys use molds but I'm sure their prototypes are all hand layup.

Clamsmasha
WA, 188 posts
27 Mar 2020 9:36PM
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I've seen a few Axis protos...CNC Paulownia bagged with carbon...still going strong.

LeeD
1422 posts
28 Mar 2020 5:29AM
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Ply works, but is heavy and uneven from the glue and the layers.
Balsa is expensive, but a joy to work with.
Insulation styrofoam is light, but hard to hold while shaping.
Blow foam has good weight and density, but often cured blow foam is uneven, making it hard to shape well.
Airex is nice, but expensive.
Poly surfboard blank 6'6" cost 70 bucks and can be sliced into making 10 front wings.

jondrums
15 posts
28 Mar 2020 8:06AM
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I love the idea of 3D printing or CNC router-cutting a mold and using expanding foam (sicomen foaming epoxy, or maybe something more obtainable). That seems like a great workflow for prototyping wings if they are designed in CAD first.

LeeD
1422 posts
28 Mar 2020 1:02PM
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That's a good part of the equation.
Finding a core that is consistent in density.
Glossing so flex is even in the wing.
Bias of glass to control flex.

Kami
1479 posts
28 Mar 2020 3:07PM
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Select to expand quote
jondrums said..
I love the idea of 3D printing or CNC router-cutting a mold and using expanding foam (sicomen foaming epoxy, or maybe something more obtainable). That seems like a great workflow for prototyping wings if they are designed in CAD first.


So, Wicka following Jondrums advice, the first job would be to design your wings on CAD or upload it from Shape3D warehouse that I can customize to your own dims for you later on.
In that case, have to find a CNC running under Shape3D program able to cut in the chosen material of building or moulding.

jt737
QLD, 410 posts
28 Mar 2020 6:03PM
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Some good info here on both simple and 3D printed moulds.

www.clearwaterfoils.com

www.easy3dcomposites.com/products/efoil

wicka
VIC, 5 posts
2 Apr 2020 9:06PM
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Thanks for the info guys, I'm not looking to go to the extent of designing something on cad and then getting it cut in the cnc. Just a fun little project I can do in the garage to pass the time. I'll have a look into the things you suggested and I'll get back yo you with how it goes. Thanks again.

LeeD
1422 posts
3 Apr 2020 3:44AM
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If you hand layup, be sure to spackle and squeegee after lamination to squeeze out the tiny air bubbles in the laminate.



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"Making carbon foil surf wings" started by wicka