LeBoeuf's generic build thread

[leboeuf]

Thanks guys!
I've never really been much of a router guy (loud and messy!), so I've been trying to get all the practice I can with using template bits/etc before I make my mold pieces.
This project gave me one last practice shot before I start making my actual ski components...

So I ended up picking up 10 8'x4' sheets of formica for $40! I'm hoping that with a bunch of release wax I can use them as cassette pieces. I think I have enough formica for a lifetime of shop built tools...

[leboeuf]

Finally got 2 full days off from work and made some progress....

New template:
The Arg's and brewskis are on loan from a friend


Molds in progress:
The router table rocked!

[leboeuf]

Just noticed I missed a pic

Lay of the land:

[leboeuf]

Another somewhat lame post.... Progress has been a little slow. We did finally have a storm roll through so hopefully I'll be able to take my skis out without driving deep into Colorado...

Hose finished:



Cat track was finished last night:


Just need to finish off the top mold filler blocks. Hopefully I'll be able to test the press out tonight

[Richuk]

Does your heat blanket end before it gets to that big flat spot at the end of the tip mold?

[leboeuf]

I probably wont pursue heat until next season.
I think I see what youre getting at though. I'll probably knock those corners off on the bandsaw if things bind up when I test it out

[EricW]

Have you pressurized it in the press yet?

[leboeuf]

I finally got the press tested out! I hid behind my table saw with ear muffs on just to be on the safe side... Kinda got my heart rate going...
I ran it up to 60psi with no major issues. I'll need to add some more spacers and trim off the sharp corners on my bottom mold, but other than that I think it's good to go.

[EricW]

Nice job dude. Depending on what my Christmas bonus looks like this morning, I think I'm going to build a similar design this week.

[skidesmond]

60psi wow, that's great! Looking good!

[Richuk]

Great work.

You might not need to cut the mold, if your cassette ends short of this mark.

Do you know what pressure you will press at?

[COsurfer]

Nice job!

[leboeuf]

Thanks all.
Eric, honestly the press was one of the cheaper parts of this. Probably about $100 for the steel and welding wire, and about $50 for the two beams and their hardware.

Rich, the cat track unfortunately bound up on the corners... On the plus side it should only take me a few minutes on the bandsaw to fix the issue.
I'm planning on running the press at 40psi.

Also the hard-board I used cracked at the tip curve. I think I'm going to cut a cassette out of the formica I picked up and see how it does. I'm kind of worried that it won't provide enough protection to keep the cat track from making indentions into the ski.

[MontuckyMadman]

we still got cattrack indentations in the tip area with 1 piece of 16ga al. we went to 2 pieces and no probs so far.

[skidesmond]

Thanks all.
Eric, honestly the press was one of the cheaper parts of this. Probably about $100 for the steel and welding wire, and about $50 for the two beams and their hardware.

Rich, the cat track unfortunately bound up on the corners... On the plus side it should only take me a few minutes on the bandsaw to fix the issue.
I'm planning on running the press at 40psi.

Also the hard-board I used cracked at the tip curve. I think I'm going to cut a cassette out of the formica I picked up and see how it does. I'm kind of worried that it won't provide enough protection to keep the cat track from making indentions into the ski.

I had the same problem with hard-board (white and brown). I bought 1mm al sheet metal. Haven't used it yet but should help. Last ski I made I used hard-board and slipped a piece of al flashing underneath the tip area. It helped. Two pieces probably would have been better.