Adam Lloyd in New Zealand has been building framed wooden boards and was keen to try bagging wood over EPS as an option. Here are few shots he sent me of his progress.
I helped him with a design in AKU and he had to convince his local shaper with a AKU machine to have a go at cutting the file for him. It is much easier to give someone a straight forward file that is thinned out for your needs with normal rails cut as well. And then it is a regular cut for them. That way it will fit with their work flow and you get a result that is easy to use. So here is the cut blank from H grade EPS. Next is to scribe the rails and cut off 10 or 15mm that will be replaced with laminated Paulownia.
Get the rails nice and square and then glue on say a 3mm strip of Paulownia. All you need is good quality masking tape, no clamps required. Do this both sides and across the nose. And the tail if you want depending on what finished shape the tail design is.
Once you have trimmed the 3mm Paulownia on all the way round the blank, you can set it up on a level bench and place some wood under the blank as you rocker bed. Check you rocker from the design / cutting file and make sure it is still there. Cut your deck and bottom skins about 5mm oversize all round and you are ready to get some glue out and laminate it all together.Slide it all in the bag on top of the rocker bed and suck it down for a couple of hours.
You can pull some pretty tidy concaves and deck roll with the bag that is for sure.
Once out of the bag you can trim it all up and you have encapsulated the foam in wood.Very simple and very efficient. Now all you have to do is laminate the rails on with masking tape once again. Simple and cost effective.
Looks like it all came out well. The board can be finished in fibreglass if you use say 3 or 4mm deck skins.Or you can use marine or floor grade varnish depending on the thickness of the deck skins and their ability to take your weight.This is a lighter and cheaper option compared to getting someone to glass the board for you.
Looks like a fun board.
If you want to get more info from Adam check out his site :
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