Detailed documentation of my next build
Moderators: Head Monkey, kelvin, bigKam, skidesmond, chrismp
Most of all because I can't think of a proper method to align the cores so damn damn precise. If they just shift by 0.1mm it makes a 0.2mm difference from left to right side of the ski already, and more than 0.4mm difference I will definitely see. So max. core shift I could live with is 0.2mm, and so far I haven't found a proper way to achieve this.
Thats the problem with pressing cap...
Thats the problem with pressing cap...
I drill 2 holes in the core and insert a dowel in each.
I put the dowel in the core and a spot of superglue on the end of it and place the core exactly where I want it. Remove the core leaving the dowel attached to the ski base.
In the layup you have to fit the cloth around the dowel, but you are guaranteed perfect core position and no shift.
On snowboards I use the same method but do it with 2 of the binding inserts.
Works for me at least.
I put the dowel in the core and a spot of superglue on the end of it and place the core exactly where I want it. Remove the core leaving the dowel attached to the ski base.
In the layup you have to fit the cloth around the dowel, but you are guaranteed perfect core position and no shift.
On snowboards I use the same method but do it with 2 of the binding inserts.
Works for me at least.
I am nobody. Nobody's perfect, so I must be perfect.
Thought about using the dovel method, but there is so much trouble I can think of that I kept away from it until now. Then next Ski I build will have wooden sidewalls, this will make everything much easier in terms of labour. But I have tons of other ideas that cause extra work again :) Well thats me, a perfectionist!
Ok, today I made some progress. First, I used my new Bandsaw to cut the excess material away. Did this with a jigsaw so far. Bandsaw is sooo much better for doing this. A quick runover with the belt sander makes the sides nice and even:
In this picture, the skis are already in place for routing the bevel on the sides. I use a simple selfmade attachment for the router. A 15° doveltail router is tilted more so the total angle is about 35-40°:
The result is great, unfortunately the pic is not too good:
The top edge is rounded by hand so the topsheet can bend over it well:
Ok, today I made some progress. First, I used my new Bandsaw to cut the excess material away. Did this with a jigsaw so far. Bandsaw is sooo much better for doing this. A quick runover with the belt sander makes the sides nice and even:
In this picture, the skis are already in place for routing the bevel on the sides. I use a simple selfmade attachment for the router. A 15° doveltail router is tilted more so the total angle is about 35-40°:
The result is great, unfortunately the pic is not too good:
The top edge is rounded by hand so the topsheet can bend over it well:
Your attention to detail is very inspiring.. I feel like a bit of a hack when I see how perfect your skis are. ;-) Respect!!
What is the white layer under your core? Is that a PU layer or something. I sawi it in your earlier pictures from above where there is a white stripe where the core gets thinner and was wondering what that is.
I used my new band saw also for the first time on Monday and was also amazed as to how fast and easy it was... and almost no dust with the dust extractor on.
What is the white layer under your core? Is that a PU layer or something. I sawi it in your earlier pictures from above where there is a white stripe where the core gets thinner and was wondering what that is.
I used my new band saw also for the first time on Monday and was also amazed as to how fast and easy it was... and almost no dust with the dust extractor on.
I am nobody. Nobody's perfect, so I must be perfect.
