Pheeps - Building Progress

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Pheeps
Posts: 3
Joined: Wed Dec 11, 2019 5:17 am

Pheeps - Building Progress

Post by Pheeps »

Thank you to everyone who has contributed to this forum through the years. It's educational, entertaining and inspiring. I continue to read and learn from what you documented, which helps greatly throughout my own building progress.

Basically, this is just a hobby for me, no real expectations or aspirations other than to build some skis and make some turns on them. I started skiing young, raced when younger and have done plenty of back country, which has me designing/building skis for groomers as well as skis for powder. Like most here, just posting to share my application of knowledge gained from this site back to the community. Maybe someone else will find it useful; hopefully I'll get some more tips from others.

My first attempt was in late 2018, a powder ski (about 120mm under foot?) which never got past the prep of materials. I made a template. I got the cores profiled, shaped, rabbeted. I cut the base material and a few weeks later attached edges. Then I learned the hard way about base warp. Base material had warped significantly prior to attached the edges and, being my first time, I used way too much super glue to attache the edges. Oh well, I still have those cores and bases just in case for later on.

No further work on skis that year.

Second attempt. Started way too late in 2019, but really wanted to try them out during a mid-January trip to Montana. So, it was a bit rushed. Not many photos, but it was a good learning experience on the full process and the finished pair skies way better than expected. Since none of my skis are powder skis (Volkl Mantra being the closest) I wanted to give that a try again, plus I was thinking powder skis might be more forgiving of mistakes and imperfections, not sure how true this is. I searched online for a ski to emulate and decided to use J Skis - the Friend. I used sno-CAD and came up with a 182 with side cut of 143-118-133. I was able to print at work and glued the template to some MDF.

Then I just lined up a piece of flexible pine to the outline of the template side cut and drilled it into place to use as a router guide. Nothing fancy, but it worked.

The guide worked well with my home made table router and a flush trim bit with top bearing. I got a nice clean edge right on the printed side cut line. For whatever reason, I was thinking I needed to have both sides trimmed perfectly, I ended up modifying this later.

Warning: my workshop is a small, 0ne car garage and we are continuously renovating our house which takes priority and never leaves enough time to clean up. It's not the cleanest nor organized.
template.jpg
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...more to follow
Attachments
sidecut 1.jpg
sidecut 1.jpg (598.45 KiB) Viewed 44 times
Pheeps
Western Washington

Pheeps
Posts: 3
Joined: Wed Dec 11, 2019 5:17 am

Re: Pheeps - Building Progress

Post by Pheeps »

Cores.jpg
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Laminating cores. I used poplar and pine, partly because I had some and it's not expensive and partly because I wasn't sure if I'd get to actually finish this pair. Mostly I just wanted to get through the process and learn how to improve, so didn't want to invest too much into the materials if I didn't have to. That said, both the pine and poplar were light and springy, all strips used were vertical grain, 3/4" wide and about 15mm tall. I can't find any other pictures of the cores through the process. Basically, after the glue dried I ran them through my planer just to get them flat prior to trimming to shape. I've now learned not to bother too much about getting both sides smooth/flat. As long as the bottom is flat, the top will be fine after tapering. This is only a little important due to wanting to reduce waste as much as possible. I've made 8 cores now and tend to get the overall thickness too thin in the end. I start of with 15mm tall strips, which after laminating are not flat; in the process of flattening with the planer I lose 2-3mm. Shooting for 12mm under foot, this doesn't leave much for the tapering process. Anyway, just a thought for later. I do have a jointer, which I plan on using moving forward to get the rough cores flat on one side, then use the planer to taper down.

More photos later with the next pair of skis. But, the planer jig is based on a few different examples I've found searching this site.
Pheeps
Western Washington

Pheeps
Posts: 3
Joined: Wed Dec 11, 2019 5:17 am

Re: Pheeps - Building Progress

Post by Pheeps »

Like I said, I was moving fast trying to get this pair done, so not much for photos.

I added maple sidewalls, tapered shooting for 2.2 - 12 - 2.2, but ended up a little under that, rabbeted for the edges and trimmed the excess with straight cuts.

Bases: In an effort to avoid base warp this time, heated with heat gun just a little prior to cutting to rough shape. Let them relax prior to routing to final shape.

Attaching edges, after this I bought many more clamps. No real issues here. Not attempting full edge wrap, so tip and tail to be cut to shape with flashing. Matched original template exactly this time.
bases.jpg
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Rushed through lay-up and into the vacuum press without any photos. But here they are in the press:
vacuum press.jpg
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Real basic camber rocker rack. I had a 14" wide sheet of aluminum bent with a somewhat tip-shaped curve and adjusted camber and rocker with shims under the aluminum. Nothing too precised, but tried to get as close as I could.

basic layup was: base with edges, vds, 22oz. triax, core, 22oz. triax. I used the epoxy and resin from snowboardmaterials.com, mostly due to not have a heat method. That said, I did build a box from foam insulation to get at least some heat.

Out of the press:
top.jpg
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bottom.jpg
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and cut to shape:
cut out.jpg
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They cleaned up fairly well, but don't win any awards for overall finish. Bases were relatively flat and just needed a couple passes on the grinder. One issue which confused me was a few little gaps between the to of the edges and the core. Thought is the rabbet was either not deep enough or wide enough, or being a vacuum press I just didn't have enough pressure. I did make the rookie mistake of mixing too much epoxy in one pot, which resulted in the epoxy setting up faster than expected.

I learned a lot in the process. I did ski two full days on these out in Whitefish, mostly tree skiing in 1-2 feet of new snow. They skied great; way better than I was hoping for. I do have some gopro segments, I'll try to get that loaded.

Pretty basic write-up; I left out a lot of detail, but just wanted to get this on here for what it's worth.

Two more pairs in the works, including one that's very similar to these. I'll get more details on that process and more photos.
Pheeps
Western Washington

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