04 sandwiching the hull

April 17, 2021

Mask the edge of board.
Cut a piece of 4oz fiberglass cloth for the whole hull of the board. Make it about 5-10cm longer than the length of the board.
Cut a piece of 4oz fiberglass cloth to reinforce the back 1/3 of the hull.
Cut a piece of 6oz carbon fiber to cover the fin reinforcement area.
Cut the Divinycel core to shape.
Roll epoxy on EPS foam. Add glass, roll on more epoxy on glass, trim glass to shape.
Roll epoxy on core material.
Put core on board. Add some tape to secure core.
Put in vacuum bag. Turn on vacuum, less than 0.2.
Place wood shape for on top of core, tape in place to secure. (It's better if you can put the wood form insude the ba before bagging, but my bag was not wide enough).

If your core material is not large enough to cover the whole board, you can attach several pieces together. I used masking tape for the bottom core. However, when I did the core for the deck, I found it easier to use gorilla glue to stick the pieces together. (Masking tape does not stick very well to the core material).
With a heavy enough application of epoxy on the fiberglass, I probably could have gotten away without having to roll epoxy onto the EPS and core material. The EPS and core material absorb epoxy like a sponge, so added a lot of uneccessary weight.