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Design and construction of a windsurfer longboard

Design and construction of a windsurfer longboard

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Published by Malcolm Jones
Design and construction of a windsurfer longboard
Design and construction of a windsurfer longboard

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Published by: Malcolm Jones on Nov 23, 2008
Copyright:Attribution Non-commercial

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11/27/2013

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Design and construction of awindsurfer longboard
By Malcolm Jones
November 24, 2008(Updated May 19, 2010)
 
Preface
The following began as my working notes when designing a windsurfer I recently built. I’d do a bit of the design, leave it, come back to it and forget what I’d done andwhich design I was going with. Therefore these notes were written primary to remindme of what I did. Once I started building it I decided to continue the documentation just in case I was every crazy enough to do it again.Thedesignwasfromscratchandthiswasmyfirstattemptatbuildingawindsurfer.I’d done small repairs before and built a canoe using a mould so had some prior fibre-glassing experience but had not done any vacuum bagging.The notes are not a step-by-step how-to. More importantly they are based on a firsttime backyard board builders experience. I’m sure there are many things I did whichcould be improved or done entirely differently. There is not that much info on design-ing and building a windsurfer. However info on building surfboards, canoes, sailing boats is more plentifully and can be useful. The best reference that gives detailed step by step information for windsurfers
was
at the website
http://www.ecboards.co.uk 
. Itis titled
Building a composite windsurfer
and gave details on building a speed board. IfoundanyinfoprovidedonthewebtobeinvaluablehenceIdecidedtoputthesenotesout there for anyone else attempting a similar project.Before embarking on building a board you have to ask the question why? If it isto save money don’t do it. The material costs equated to roughly half the retail priceof on equivalent board. However if you factor in labour there’s certainly no savings.Realisticallyitwasequivalenttoamonthfulltime. Itook6daysoffworkandspentthe best part of a month worth of weekends on it. It took far longer than I had anticipated.This is partly because it was my first time and I was learning as I went. I’d make smallmistakes which then took time to fix.For me the motivation behind the project started with an old raceboard that wasleaking. I’d previously fixed the centre board box and suspected it was leaking. SoI took the drastic step of cutting a 1
×
0.1m slot down the middle of the board andrebuiltthecentrebox. Itturnedouttherewasnowaterthere, howevertherewaswatergetting in the front. The board was already 18kg and with more major repairs would be getting close to 20kg, also it was 20 years old. Time for a new or better 2nd-hand board. Only problem is new boards of this kind are hard to get. Exocet and Starboardhave started making them and Mistral appears to resurrecting the
equipe
. On the 2nd-hand market a couple of boards appear every 12 months Australia wide. So with thecentreboard box builtandsome vacuum bagging skills acquired Idecidedto go alltheway and build from scratch. I also liked the idea of designing and building myself.Would I do it again? Probably not. Overall I was happy with the result. Whileit’s obviously an amateur build it came out under weight and without any flaws thatwould effect performance. Basically this is my light wind “sailing” board, maybe I’llgiveracingagobutitwasn’tbuildwiththatinmind. I’dtriedwide-styleearlyplaners but found them a bit one-dimensional. My biggest sail is 8.5m
2
which on a 85cm wide board gives me planing threshold of 
8knots minimum (i.e. realistically a “steadywind
averaging
10knots). But if it’s a summer’s day with an average 8knots I’d betempted to venture out and end up struggling in the lulls. So I experimented with anold raceboard and found I was having heaps more fun in the 8-12knots winds.
 
Contents
1.1 Maximum dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Rocker profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Deck centre-line profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Vee, concaves, tail kick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.5 Planshape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.6 Deck cross section and rails. . . . . . . . . . . . . . . . . . . . . . . . . . 61.7 Data files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.8 Design weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.9 Material costs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.10 Time required to build. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Design of centreboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.1.1 Aerofoil section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.1.2 Planshape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.2 Construction of centreboard. . . . . . . . . . . . . . . . . . . . . . . . . . 162.3 Centreboard Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Mast track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.2 Finbox and Footstrap plugs. . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Shaping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.1.1 Templates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.1.2 Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.1.3 Rocker and deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.1.4 Vee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.1.5 Planshape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.1.6 Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.2 Laminating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.2.1 Carbon/HDF to bottom. . . . . . . . . . . . . . . . . . . . . . . . 284.2.2 Carbon/HDF to deck. . . . . . . . . . . . . . . . . . . . . . . . . 294.2.3 Fitting the fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

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