Ski bases are thin sheets of plastic made from extruded or sintered UHMWPE
(ultra-high molecular weight polyethylene). These plastics are specially
designed to absorb wax and also bond very well with epoxy.
To prepare the base material for layup simply cut the material to the desired ski
shape. This is done
most accurately by using a template along with a cutting tool to trace the
template. Cutting tools can range from a simple sharp utility
knife to a router.
Step 1: Prepare Cutting Surface Before you begin any actual
cutting of the base material, we highly recommend preparing a cutting surface
especially if you plan on using a router. This can be any smooth piece of
material that you won't might cutting into. In the picture below, some
scrap piece of particle board from an old shelving unit serves as our cutting
Step 2: Clamp Template Onto Base Material Clamp your ski template tightly onto the base material. It's
important that neither the template or base material move while you do your
cutting. Double-sided tape along with several clamps should be enough to
keep the template in place. You'll notice that the clamps will get in the
way while you're tracing the template. Simply reposition the clamps
when you get near them to get a continuous cut.
Step 3: Cut the Base Material Cut the base material
by slowly tracing the template with your cutting tool.
Depending on the cutter, you may have to adjust the size of the template
to get the correct final dimensions of the base material. For this example, a 1/4" diameter straight
router bit fit with a 7/8" diameter ball bearing was used to trace the template
To compensate for the diameter of the ball bearing and router
bit the overall shape of template was reduced by approximately 0.312 inches
(8mm) in order for the base material to be cut to the desired dimensions.
If you plan on using a knife to cut the base a reduction in the template's size
does not need to be made. Slowly trace or follow your template with the
cutting tool of choice until you have cut out a pair of bases.
Step 4: Finishing the Cut Depending on your cutting tool,
depth of cut, speed of cut, and other factors you may end up with bases with
edges that aren't
Finish the bases by using a sharp razor blade to trim off the excess material followed
by a rub with some fine grit sandpaper to get the sides all cleaned up.
After you're done, the base material have a nice smooth finish
that is prepared for the next step of attaching the metal