Creating A Template
Overview Once all the
design parameters have been specified, the next step is the draw up the ski and
create a template. Templates are used as guides for cutting base
material, determining sidewall placement, etc. The best method for
producing an accurate drawing is to use a CAD program. Free programs are
readily available on the web and any program with good drawing and printing
support will do. Below is an outline of how to draw up a ski and make a
template used for cutting out base material. Templates for other purposes
are made in the same manner. For the following demonstration
Turbocad, a popular free program, was
Step 1: Set Up Page Size First set up the page to fit the intended ski size.
Usually this can be done by manually inputting the sheet size (for this example
we use 200mm X 2000mm).
Also set up the document's units to metric and turn on the
Step 2 Use the 3-point arc tool to draw in the turning radius,
or side cut, for both sides of the ski. Most programs allow for manual
input of the arc points (tip, waist, and tail width) to provide for a more
Step 3 Now use the spline tool or any of the arc tools to draw
in the tip and tail shapes. This part can take the longest to perfect but
once you get used to the tool functions it should be relatively easy.
Step 4 Most CAD software allow for full scale
(1:1) printing. It's easiest if you have access to a full size
plotter but it's also possible to print the ski shape over multiple pages.
These pages are then taped together to form the full-sized paper template.
Make sure you save the file for future reference. Typical file
formats will include the *.DXF extension which represents a drawing file that is
compatible with numerous programs including Adobe Illustrator.
Step 5 Use some spray adhesive to glue the paper template onto
wood or MDF (1/4"+ thick). Carefully cut out the ski
shape using a jigsaw. It's best to get as close to the ski's outline
as possible but it's better to leave excess material rather than cutting away too much.
Use a sander to get rid of the excess wood to leave a nice, smooth template.
Step 6 The final step is to mark some parameters on the
wooden template. This step is optional however it can help out later on during
ski construction. Parameters worth marking are the location of the ski's waist,
tip and tail contact points, and the longitudinal center line of the ski.
Read how a template can be used in for the base
Sample CAD files The drawing files for some of the skis we've
built are available below. The *.DXF files should be compatible with
most CAD programs and can also be viewed in Adobe Illustrator. Right
click each link and select "save target as" to save the file to your computer.