Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 5:42 pm

Hey guys, with winter upon us I’m getting less water time so have decided on trying to build a wakefoil.

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I started with joined pine (so it didn’t twist) for the foil, shaped it with an airfoil and covered with glass.
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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 5:45 pm

Next was the rear fin, I used 2 pieces of 3mm ply glued then shaped again with an airfoil shape. I covered this in glass also.

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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 5:49 pm

The fuse joining the two was made from the same pine but with 3mm ply glued to each side, shaped then screwed and epoxied to the foil and rear fin, again with a covering of glass with an extra covering across the joins

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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 6:16 pm

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Again used the joined pine for the mast with 3mm ply glued to each side. Shaped again in an airfoil, drilled down the centre where 2 6mm stainless threaded rod were epoxied in. Drilled the fuse and bolted the mast to the fuse. Again wrapped the mast in glass.
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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 6:27 pm

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After routing out the mounting plate I left enough space (about 2mm) to allow a wrap of fibreglass and carbon fibre through and over the top of the mounting plate. I layed another layer of glass over that and epoxied the glass and carbon fibre down the mast.

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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 6:36 pm

A solid sand between all applications of resin is required, next was another layer of glass under carbon fibre all the way around the fuse with a big overlap of the last layer making sure to get all air out from under each layer.

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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 7:30 pm

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Another carbon over glass with a wrap around the mast to lock it in.
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Last edited by Feetfirst on Wed Jun 26, 2019 7:52 pm, edited 1 time in total.
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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 7:33 pm

I also drilled out the mounting plate with a 20mm hole saw where the mounting bolts were to go. I then filled this with resin so that when I bolt it all together it doesn’t crush. Not sure if this is going to work any better but it’s all a bit at an experiment.
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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 7:37 pm

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Same thing with the foil but it was carbon over carbon, once the resin cured it was stiff as. Made sure there was heaps of overlap for the strength.
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Re: Wake foil build

Postby Feetfirst » Wed Jun 26, 2019 7:55 pm

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Re: Wake foil build

Postby JBWake » Thu Jun 27, 2019 8:16 am

That's awesome.

Only thing I can think of is that as you have glassed everything up, you do not appear to have left much allowance to adjust anything once you try it.

Great project!
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Re: Wake foil build

Postby will » Thu Jun 27, 2019 9:02 am

So awesome mate! Looking forwards to seeing how it goes!
Enjoy the ride. Any time on the water is good time!
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Re: Wake foil build

Postby Feetfirst » Thu Jun 27, 2019 8:35 pm

Thanks Will, we will see.

JB you are right, I was thinking about adding a wedge to the tail plane for lift if needed. My biggest concern is strength.
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Re: Wake foil build

Postby Feetfirst » Thu Jun 27, 2019 8:40 pm

[classified][/classified]
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Drilled the board to suit the wakefoil, packed the top of the mounting plate with a hard drying glue to get the form of the board curve. pressed that onto the board over a piece of glad wrap and hopefully when that sets it will bolt down solid.
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Re: Wake foil build

Postby Feetfirst » Fri Jun 28, 2019 10:30 am

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Re: Wake foil build

Postby will » Tue Jul 02, 2019 7:36 am

When is the maiden voyage?
Enjoy the ride. Any time on the water is good time!
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Re: Wake foil build

Postby Feetfirst » Tue Jul 02, 2019 8:52 am

Unfortunately not yet Will. I’m in Newcastle. With any luck early next week if I can get a winter crew together.
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Re: Wake foil build

Postby will » Tue Jul 02, 2019 10:06 am

I'll be eagerly awaiting pics & video! Hopefully I'll be getting out today for the first time in months. It's overcast and cold but it'll be so worth it!
Enjoy the ride. Any time on the water is good time!
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Re: Wake foil build

Postby Feetfirst » Fri Jul 05, 2019 8:56 pm

Hey Will, how was your day out??
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Re: Wake foil build

Postby will » Wed Jul 10, 2019 7:45 pm

Goods mate! Only the driver and spotter in the boat so very little wake but I managed all my usual inverts. Pretty stoked as I haven't ridden boat in ages. :)
Enjoy the ride. Any time on the water is good time!
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