Ski Builders Forum

could you stack 2 or 3 layers of p-tex and cut them all at once?

Sure, just make sure you've got some really strong clamps holding it all in place, I'd worry about the layers shifting.

The idea about using the hand-planer on the ptex after routing - I would worry about consistency between skis. Really, if you've got a good template (which is very easy to make with a bandsaw and some sanding), cutting out the ptex with a router is very easy, and very fast. I just use a normal cheap straight edge router bit with bearing.

I cut out 4 bases yesterday, in maybe 10 minutes, for two different pairs (two different templates). Other than cutting out the corners for 3/4 edge wrap (I do that by hand with a razor blade), after routing the base is ready for the edges/layup.

I tape, face to face, the two layers of base material together. Then I clamp them to a mdf template and use a router with a flush trim bit to follow the template. I vary the size of the bearing to increase the overall dimension of the ski if I want wider skis. I have to shave some ptex strands off the bases.
I like the steel templates used in this video at 4:04 http://www.igneousskis.com/custom/wp-co ... gneous.mov
Judging from their setup, I think they used a knife to cut their bases.

another day I thought about new way to creating templates ......on profiling jig. First create negative of sidecut both sides at the same time of course This way both sides will be identical. After that on simple router circle cutter Jig make tips/tails coverture. this way 4 sections put together will create negative of the mold or maybe even mold itself ( this is just an idea).
how about it? I think it should work.

I make half of a template on the factory straight edge of a mdf trim board (drawing a line and following it with thin flexible mdf and jigsaw/router/belt sander). Then, with a router (flush trim bit), I copy it on the other edge and put these back to back and create another whole template.
If I spread the tips of the 1/2 template I can maneuver the centers of the edge radii on subsequent templates. This method also ensures symmetry in the final template.

Does anyone use metal templates and a knife or a die cut method to cut out bases?

Richuk was getting steel templates cut out by lasers or water jets if I recall correctly. And was using the cutoffs in the cassette, which is pretty killer.

twizzstyle wrote:Richuk was getting steel templates cut out by lasers or water jets if I recall correctly. And was using the cutoffs in the cassette, which is pretty killer.

That's a damn good idea.

I cut all my bases with a cnc drag knife, but a roller bearing bit on a tile router with an mdf template is much faster.

Another question for ya Brett - how do you hold down the ptex when cutting with the drag knife? I'm not sure if you've got a vacuum hold-down system or not, I am NOT planning on doing any vacuum, just machinist clamps and a grid of a few hundred t-nuts.

spray 77 for now

I got a local firm with a CNC to cut me a whole range of "radius rulers". from 10m to 30meter plus a couple of s-shapes. I now use these with a router to make templates. The s-shapes for tip and tail molds and transitions between curvs. Now I can make all the templates my self and they will always be correct.