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[SURFFOILS]

Guys, I had a setup and then moved house so now Im keen to setup again but instead of copying a  standard surfboard shape and construction again what do you think would be the MINIMUM layers that would work using a ply and foam vacbag ?
 I know theres all sorts of foam thicknesses and ply can come in 1mm so maybe 5 thin layers of ..   ply/foam/ply/foam/ply ?
 Im looking at a Machado board and its so thin that its almost   a uniform thickness with just rocker, so considering that people can ride almost any shape, the only question for me is what would be the minimum components for strength ? 3mm ply/20mm foam/3mm ply?
 Im thinking to just 'go for broke' with it, irrespective of the looks.  'Bly sky thinking', all that sort of wild silliness. What do you reckon??

[lemat]

You just want to glue?. No fiberglass ?. Wich foam, wich glue?. Look at molded wood boat: thin strips of wood glue with epoxy with pressure. I see a 6m boat build with 9mm wall : 3x3mm flex okoumé ply wood band in form and glue with epoxy, finish is light fiber+epoxy on both side. Really strong and light.

[SURFFOILS]

Thats some great ideas !!
 Yeah , if the layers are strong enough, why use fibreglass? I hate sanding the sstuff !!!
Shouldnt it be strong if you get enough layers , kinda like laminated wood ?

 So Im thinking thin layers of foam and maybe ply or balsa in amongst it, all held together with just epoxy resin.

 Do you think the epoxy resin would be strong enough over wood or is glass essential ??

 I read somewhere that a guy just put Cabots exterior floor varnish over a ply board...
 Sensible or stupid ?

[lemat]

They use fiberglass for better water proof and for better puncture resistance but you can just use nautic varnish. For gluing put silice colloidale in resin for thixotroping.

[SURFFOILS]

Thanks for the detail. Im trying to work out if I use a 10 mm XPS hull layer on the Open Sandwich, and put 4oz on the outside and 2oz on the inside, will it be strong enough to hold the contour as well as be surfable ?
I'll look into it a bit more.

[lemat]

I don't think that it'll be strong enough. On salomon blue board, hollow too, they put a lot more fiber on both side of XPS sheet (carbon for inner bottom). Put at least 6oz for inner side.

[SURFFOILS]

Thanks again Lemat.

[SURFFOILS]

I found a local veneer supplier, heres a few pics of what I got....
 If the attachments dont show I'll put them onto Photobucket and drop them in later. Any hoo, Im going ahead with a 10 mm XPS sheet and putting a 6oz both sides and then the veneer and a 2 oz.
 Ive got a ton of Innegra, could I replace it for the 6 oz Im wondering...