ฝัง
- เผยแพร่เมื่อ 2 ต.ค. 2024
- I built a surfboard blank mold out of expanding foam so I can press my own blanks from home. Was it worth it? This took me a couple of months to build and it still needs some tweaks. This will be useful when the shop I buy blanks from runs out of blanks.
I should be able to produce a PERFECT blank once the kinks are worked out
#surfboard #surfboards #surf
@HANDIY doesn’t look as clean as yours 🫠
10% OFF SHAPING SUPPLIES
greenlightsurfsupply.com/paulzeye
I've been retired from aerospace for a long time but back in the day we were building prototype skin layups on foam tooling. After the initial shaping the foam was coated with gel coat and hand finished. Before laying up the skins the skins were coated several times with a liquid mold release agent. The density of your blank is a function of how much foam is allowed to escape. Maybe some carefully placed vent channels around the rails that can be easily trimmed when the blank is removed would help control flow and density? Your concept is valid so don't give up. Looking forward to your future efforts.
Whooaaa very cool! My initial plan was to clean up the foam mold and glass the foam like you would a surfboard or a boat, but I realized the plastic seemed to release very easily from the foam. I do think it would be cleaner if I had done the fiberglass and hot coat over it. Is that different from a gel coat?
I did have the thought to have some relief holes on the top, but wasn’t sure what size to drill in. The rails would probably be a better bet though so the foam in the middle receives the most pressure.
Relief holes on the top will help you get more even foam density. Allowing more pressure in the middle may push too much foam into the outside crust that you skin off anyways leaving lower than ideal density in the middle. I made bio-based pu foam in a company that partnered with arctic foam (the blank you modeled after) and taking hardness at different layers of the foam was one of the key metrics in evaluating a formula or a mold's performance@@paul_s-eo
In the 1970s I worked for Midegt Farrelly in Sydney , Australia and he blew blanks by making a hinged 2 part concrete ‘coffin’ opened by an engine hoist. I blew thousands of blanks in those molds. Extremely heavy but worked well.
So cool! If I had the space, time, and money I would probably give the concrete mold and engine hoist a go.
Clark foam of California also used concrete molds
@@paul_s-eo What about sand casting? lots of vds on this type of casting.
here is just one:
titled: Sand Casting Foundry UK, Casting Foundry UK, Sand Castings Manufacturer
channel Engineering & Developments Ltd
good luck. Keep trying.
You'll get it, you can make molds out of fiberglass and wood. Boat builder style, then you can build hollow boards with gel coat outside. Use a good form release for fiberglass and it will look flawless. I'm a concrete worker and it can be done however it will be heavy and fragile. Plastic cement with sand @cement 1:1.5 sand , low water content , mix it thick like creamy peanut butter and it will be strong at 1"thick. Use steel reinforcement, and use water to cure the mold, you will have small bubbles as voids that can be filled with epoxy so smooth the mold after it cures, cure takes 2 weeks to be strong, best to keep some moisture in the mold for a week.
I’m definitely leaning towards the wood and fiberglass option if I ever try and tackle another mold build! I wish it were easier to carve out the wood to form. I have an idea in mind and will eventually muster up the courage to give it another go!
@@paul_s-eo glue gun small strips of veneered chip board to create a rough flange around the center line of the rails use plasticine to fill the void. Apply release agent like pva or wax. 2x gel coat layers 2x layers of 600g chop strand using standard resin then 4 to 6x layers with tooling resin. Glass in wood beam for strength and make a stand for the mold which can also be glassed in.
Once mold is released from the plug sand back any imperfections in the flange and grade the gel coat to a high gloss.
Repeat for the second half.
This will give you a classic pop out mold
This sounds very complicated to the untrained reader (me), but in application (if I knew a couple more of those items and saw it being done in person (or video) I may be able to do it! I guess I can TH-cam to see if anyone has made a mold using the technique you just described.
I will definitely look into it in the future! Thank you 🙏🏽
I think the voids are due to air pockets. Try drilling holes in the mold to let the air escape when the foam expands. Maybe putting three to five holes along the rails and ends of the board shape where the two halves of the mold meet. This way, any foam that expands into the holes won't prevent you from separating the two halves of the mold when the foam cures.
Also, maybe consider using plaster as the mold material. It's lighter than concrete and may be cheaper, but watch the quick working time. You may have to mix fiberglass or horsehair or straw in to it for strength.
Good luck.
Also, it may tend to crack
Good luck.
That’s a very good point - like creating some relief valves? That is something someone else has mentioned too! I might be giving that a go at some point. I did consider plaster but as you mentioned that it will likely crack. We’ll see how this journey pans out in the future 😆
We know first hand how hard this process is. Good on you for trying!
Haha thanks. Yeah, you guys would definitely know! Wish you guys had more suppliers here in Portland.
Don't buy concrete, use cement for your mold, but instead of using heavy rock aggregate and sand, grind up styrofoam, and mix that in. It will make "aircrete" which is like concrete, but extremely light due to all the foam taking up the space, and you won't have the expansion problems of foam for your mold. Also add in some fiberglass "rebar" that you can get cheaply at home depot.
After your mold cures, seal it with 511, and you can even paint it with epoxy to limit the amount of mold release needed when you fill with foam. As others mentioned, leave some expansion holes for the foam to come out in a controlled manner around the perimiter that can easily be trimmed off.
I didn’t know you can make aircrete with already expanded foam. I thought you had to use foam from dish soap and mix that in with cement. That’s good to know. Thanks for that advice. Might give it a go in the future.
Is fiberglass “rebar” just rods of fiberglass?
I read the article I think was in Longboarding Magazine about a Venture Company that started making these same pour in foam modes as you did. The company is well known in Ventura California. Bespoke, I just find it easier to copy the sled used by Clark foam. That was a top and bottom contour jig where the hand planer is mounted to a roller that rides on both sides of the plywood contour templates. That takes the block of foam and turns it into a surfboard blank. From there they process it further. I think it is a hot mold like a hot knife or even just cutting it with a carpenter hand saw.
Super cool! So they basically made a cnc machine with some plywood jigs and planer?
That's a neat idea
Seems like there are a hundred different ways to do this - and I chose the one that made it super difficult!
Back to the drawing board! Inventors are great people! I remember seeing the first foil board riveted, aluminum, and under hiding!!
Hey man, been thinking, it’s a bit further away from a full DIY but couldn’t you get a 3D model of the blank you want to create, get a CNC or something similar and dig out the negative of the board in a « brick » of a material (tbd), I’m not familiar with 3D printing and all of that stuff but maybe creating the mold out of something printable and then blasting a thin layer of cement on the mold so it’s even and clean and on which the board material/foam would not stick to… just an idea, maybe it’s not doable, I have no idea 🤷🏾♂️
Cheers 🤙🏽
Hey,
I had a similar idea using a cnc but I really don’t know the first thing about cnc’s! Probably the best way to get a clean mold. I wish I knew more about 3D modeling and other things. I like where your heads at! I’ll be looking more into it when the cold weather creeps back in!
Now that the weather is warming up - it’s time for adventures!
Portland represent! Nice work.
Haha 😆 thank you 🙏🏽
Fiberglass the inside of the mold for more consistent shape and make a pour hole at one end. Pour the foam into mold when it’s vertical
I never thought to pour it vertical. That definitely sounds like it would work. When I get back on that project I will definitely take that into consideration! Thanks 🙏🏽
Good on you for trying! Never give up!🤙🏼
Haha thanks! I’m excited to get this one glassed! I think I can get a few decent blanks off of it after some tweaks!
Q: what were the fumes like? Gnarly or so-so?
@@paul_s-eo Have you thought about "Sand casting"...maybe this would work. lots of vds on y. t.
here is one vd titled: [ Sand Casting ] - Learn More about Sand Casting Process
on channel SHArPEdgeGlobal
also look up vds on "sand casting resin". you could make a sand cast wtih resin then put spray the foam inside for your surfboard blank???
just a thought. keep trying. 🏄♂
i make my blanks with a hotwire and a block of styrofoam. Vacume bag sheet foam on to the shaped blank, bottom then top. Vacume bag the glass and carbon on the outside after reshaping the hard foam. Or just glass the styro with epoxy and glass/carbon. Use 1,25-2lb density foam.
Are you using EPS?
yes the EPS is anather word for styrofoam@@paul_s-eo
I may have a go with making my own eps blank at some point.
The eps blanks are easy to make once you are rolling. you can also use extruded styro which won't suck up water. Like the blue insulation foam at Lowes. more work to shape, and can delam later if you dont do a couple tricks.@@paul_s-eo
would be interesting to have a rough cost breakdown of 1. what the mold cost to build 2. how much the cost of a blank is after you‘ve done the mold
The mold would’ve cost around $225 but ended up costing probably $350 bc I had to redo it. The foam I bought for the actual blank cost $430ish (that’s with shipping). I calculated that each blank that size is around $115 and if I can get 10-11 blanks - I should still save $45ish per blank (even with redoing the mold)! And from here on out each blank would cost at $43 since the mold is done ✅ Hope that helps
dude props for the attempt! tbh its inspiring to see a moonshot project not go at all to plan, for all the great content on youtube from the pros, its very relatable to see the "what the fuck..." moments on here as well. watched to the end and really enjoyed it. good onya!
Thanks man, that means a lot. It was definitely a risky project and spent a few hundred to make it happen (due to mistakes). I really appreciate you for watching until the end! 🙏🏽🙏🏽🙏🏽
Make a fibre glass mould in 2 halves,so then you have left and right halves then use you're expanda foam for blank ,glue you're stringer in between 2 halves ,then shape her up
Ooohhh - I didn’t even think to do it in two halves! That’s a great idea! I will definitely keep this in mind if I decide to give it another go. Is this what you’ve done?
No I have not made a board blank but you have more time to work you're product in same amount of time for half the finished result ,it's like ok you paint aboard,paint goes off and you only get half painted ,mix half paint up ,then do another mix of paint ,so paint board in 2 applications ,hope this helps,just try on a little 12 inch model good luck
@dudleygraham7178 that’s true on that part but my only concern would betting each half out of the mold. It would have to be two halves that are also halved in the other direction to get it to unmold. I would think it’d be difficult otherwise, but may it wouldn’t? 🤔
That problem has been solved already, you can make a mold out of fiberglass (as used in boating and aviation), if you have the money you could have one made out of aluminum
I haven’t seen one on here, but I’m sure it’s out there. I have thought of doing that but wasn’t sure if it would need reinforcing.
I probably don’t have the money to make an aluminum mold though. I’ll probably stick with this mold for now and try and get it dialed in.
You never know till you try
That’s right! I still think I can get a few good blanks out of this mold. Gotta risk it for the biscuit 🤞🏽
Always wondered how a PU foam mold would work out. Looks like with a bit more foam that blank would have come out complete. Thanks for posting and contributing to the research!
Haha I guess it works out good, but not great. Gotta little more tweaks to make. I’ll def be using more mix on the next ones. Thanks for the inspo!
My first blank looked like yours as well. In order to get a good blank it helps for the blank to be under pressure so there needs to be just a little more foam mix then the space it will occupy. This will also increase the density of the blank. Constricting expanding PU Foam creates a lot of pressure. I can see the top part of my concrete mold lifting up, the wood casing, the hinges and locks make cracking sounds as they take the load from the pressure. I totally understood when you said you where scared haha my hands where shaking the first time, 25 seconds to mix, pour and close the mold is not a lot of time.
@@HANDIY that’s crazy! I can’t believe it does that with concrete! I trialed another one but that ended up skinny in the middle. Definitely seems like I need to add more mix and more on the middle.
The foam is so powerful! It ripped out one some of the screws of the latch!
I wonder if I over add the foam - this form is done for! 🥹
I’ll add more reinforcements and hope that the 4# density foam mold can withstand it! Yeah, it really is scary!
Are you still making boards from your mold?
@@paul_s-eo @paulzeye_surfboards its been a while since i popped out a blank, i've been obsessing with hydrofoil building lately, but my mold isn't going anywhere, next time i snap a board i'll use it for sure.
If at first you don't succeed....great perseverance there man. You'll get there.
Thank you 🙏🏽
(I almost didn't post this), I almost watched it. 🙂
Hahaha - thanks for watching anyway!
you might try aircrete/styrocrete for the mold? i don't think you should give up either. great concept!
Thank you 🙏🏽
Aircrete is a great idea, but I want to refine this one I’ve made and see if I can get a couple of blanks out of it! I will get to work on that at some point 😅
Use molding plaster for a perfect finish. Probably lighter than the concrete but not as strong.
How much of that do you think I would need for a project like this? I’m worried it can get pricey real quick.
What about sand casting? lots of vds
here is just one:
titled: Sand Casting Foundry UK, Casting Foundry UK, Sand Castings Manufacturer
channel Engineering & Developments Ltd
Hey, thanks! I’ll definitely look into it. 🙏🏽
@@paul_s-eo your's welcome. ALso look into "resin sand casting" take care
Very cool! There is a light concrete (with styrofoam), maybe together with a chicken coop wire inside to give structural support, it could work.
Thank you 🙏🏽
Is that the same as aircrete?
@@paul_s-eo Light concrete comes ready to use (with small styrofoam pieces), you just add water.
The aircrete have a liquid foam (like dish washer detergent) added to the mix on site, so more infrastructure.
But I guess the results are similar in resistance and weight.
Probably a silicone mold would work too. Also you need to use a releasing agent on the board to avoid getting stuck on it.
Nice try.
😂 if you can surf this alien thing you're the best 😉😄
Hahaha that’s the plan! I wish it were that easy to be the best. 😆
Ye this is cool xnd all but like you can buy blanks cheap enough.
Let me know if you need a mold cnc milled.
That’d be sick! Are you in Portland? If you are - how can I reach you?
A blank cost $130
@@michaeljarosinski5595 some are even cheaper from where I buy! 🍻
What was the spray you put down before the plastic sheeting? Great effort. I bet you could perfect the process.
Hey, thanks! It was a 3M adhesive to try and make the plastic stay on the mold. That obviously didn’t work 🥲
I am going to work on some of the kinks and do another run at it sometime this month! 🤞🏽
@@paul_s-eo I see. Ive seen molds covered with car wax to prevent the resin or epoxy sticking. The 3M was for the opposite reason. In theory it sounds like the 3M would have worked. It's funny how real world molecules do their own version. Props for the effort on the mold tho. Very interesting. I subscribed to your channel. I used to shape surfboards in CA 15-20 years ago. I didn't make that many, but I still have about 10 boards I made for myself that I still ride. I moved to the East Coast, but I've surfed a few winters in CA for a few months at a time recently. Definitely miss those west coast 4-6 foot glassy winter days.
keep pushing
Thank you 🙏🏽
👍🏾 for trying
🙏🏽
I reckon a properly braced fiber glass mould would do it. You'd have a bit more time and control and be able to get a pretty flawless finish.
Do you mean using fiberglass over the blank with some sort of barrier? I would think that would work if you’re able to reinforce it afterwards? That was a thought I had prior to taking on the project.
Honestly think using a rocker
Mold and cutting out individual 2x4s and gluing it up might be the way to go? Might be a future project!
Would a fibreglass mould work? Might want a bunch of ribs and strengthening but might be an idea
I’ve thought of that, but the ribs for reinforcing I haven’t thought of. Something worth considering indeed 🤔
I made a surf board out of 2 pieces of 2 inch ESP 2 lbs. foam sheets 2 X 8 ft. To do this I took a surf board rocker I liked. Copied it to a masonite sheet and cut the sheet to the new traced rocker. Then I took two 2 x 8 ft. long sheets of 1/4 inch thick CDX plywood and traced the masonite rock to the top side of the 2 ft. wide area. Installed 2X4s on both the sheets rocker lines. Like building the ribs for a Thrasher Skate board plans fly ramp. Laid a top sheet on the ribs and screw it down. Put the Epoxy in between the 2 foam sheets. Compressed the two sheets of foam to form the new found rocker. My fastest surf board yet. 8 ft 7 inches.
I have thought about doing something similar but I decided to go the PU expanded foam route! I may give this a go in the future as well!
Would love to see how it turned out if you have any pictures. Do you still have the set up that you used for compressing it to shape?
I kept the two plywood sheet sides with the rocker curve cut to the same on both. I used 2 ft. long 2 x 4s to support the 1/ 4 inch plywood top as the molds shape.
@@paul_s-eo
You gave it hell Brother. I'll bet Harold Walker is smiling from his grave.
Haha I hope so
Dude! You move really fast at times!
Awesome video - thank you. 🤙
Hey, thanks! 🙏🏽
Do you mean the editing? I do speed up a lot of the build otherwise it would be a 5hr video 😆. Thanks for watching
I want mold I am Sri Lanka
Maybe you can try and make one and see if it turns out better than the one I made? Mine didn’t turn out amazing haha
@@paul_s-eo thank you so much 🙏 you came Sri Lankan big market have surfboard
Please keep doing this and refining it, this is cool!!
Hahaha thank you 🙏🏽 that project is currently on hold atm, but I’m definitely planning to keep refining it in the not so distant future 🤞🏽 and hopefully get a couple of good blanks out of it!
Why not use a CNC machine
I would love to but I don’t have one. I might look into how much it would do have a local shop do it. I wouldn’t even know what information to give them to cut what I need 🫠
@@paul_s-eoThey can refine the design perfectly with no flaws in the design. You might think that a board looks perfect when it's hand shaped but it's not.
Ohhh I thought you were referring to the mold getting cnc’d. I’m working on my shaping so that’s why I’m starting from blanks. I enjoy the shaping process.
@@paul_s-eoI've shaped two boards and it's difficult but fun but at the same time, you don't make that much money at it.
I made my surfboard mold using concrete... Definitely WAY too heavy and very hard to bring up to temp... I got one surfboard from it, but all in all an epic failure
Oh man! I didn’t even consider the concrete temp! It’s currently cold where I’m at so that would’ve made a huge impact. I’m hoping to get at least 5-6 good blanks out of this first batch of foam mix!
I think getting a cnc shop to cut in a precise mold into glued up 2x4’s would be good! If not that, I thought about using a rocker template and cutting each individual 2x4 and glueing it up after. That might be my next attempt 🤷🏻♂️
Yeah, I like your method! I've been using a homemade po' boy carbon fiber for smaller molding... Basically just fiberglass, epoxy and graphite with a mold releaser @@paul_s-eo
@matthuber9936 I can’t imagine it. I did buy a mold release too, but ended up using this plastic sheeting instead. It seems to release really well after it’s cured. I’ll probably have to use mold release if I make it out of wood. We’ll see what happens!
When studying I moulded metal in sand. Worth a try!
@j_cbat do you think that would work using aluminum cans? How would you get the outer shape of a surfboard blank? I can’t seem to imagine it.
the best looking kicker board i've ever seen.
Not sure what a kicker board is but I’ll take it 😬
Good on you Bro. Keep us posted.
Thank you! I’m currently taking a break from that project due to frustration but I will surely post something on it when I make some modifications!
I have those surf board pics but I need your email to send them. Let me know.
Do you have an Instagram by chance? You can find me at Paulzeye surfboards on there too. If not my email is eopauls@gmail.com