Building an Efoil From Scratch (Need Help)

[JaydenDSG]

Hello everybody,
I’m building an Efoil from scratch. I plan to use a 3D printed core for shape, then reinforce it with carbon fiber. I have a rough CAD assembly for my plan so far. I’m looking for feedback on the design before I start the building process.

I’ve spent most of my time working on the mast-to-fuselage connection. The plan is to clamp the motor around the mast, then have the fuselage wrap around it and screw everything into the mast, and finally cover the fuselage with panels to maintain hydrodynamics. The bottom of the mast will be aluminum for the screws to tap into, and the screw holes in the fuselage will be filled with epoxy and redrilled.

Here is a picture of the clamp.

Right now, I’m working on the rear fuselage for the stab.

I want to mount it between the front of the motor and the prop guard, but this would leave me with a weird joint. I could connect this to the main fuselage and run it under the motor if need be, but I’m trying to avoid that for simplicity and hydrodynamics. Any suggestions?

I’m looking for any feedback on things to change before I get too far.

[Foilguy]

It looks quite similar to Fliteboard

I would suggest you design it so the prop guard is removable

[DutchFoiler]

Get a gong mast, mount the motor at the complete bottom, and CNC cut a custom bended fuselage. Will do the same, will save you all the hassle.

Your drawing looks great, but don’t get me wrong, bringing this idea to live, will be a headache. Where will the cables go? Which wings will you use?

Sometimes it’s better not to reinvent the wheel. The gear is already there. You’ll only need a custom cut fuselage.

[HOF]

You will include a 65xxx motor in there? Actually a great idea. When do you plan on finishing?

[JaydenDSG]

You are absolutely right, not reinventing the wheel would be the smartest approach, and just buying gear and modifying it would be the easiest, but my goal is to save money. Your suggestion isn’t lost on me, and I’ll probably regret this choice later, but this is the plan for now. This week’s plan is to make a test piece the same way I’m planning to make the rest.

Here is the rough cable track:

It’s still going to get polished up, as I’m going to change the mast profile slightly, but this is the idea.

I’ll be making my own wing. The wing doesn’t seem too hard compared to the rest. A 3D printed core that is reinforced with CF.

[JaydenDSG]

Yeah, I’m using the Flipsky 65220 motor. Being optimistic, the plan is to have this done sometime this summer.

[DutchFoiler]

Highly appreciate your determination, and as far as I can see you seem very knowledgeable with the drawing part. But just saying, a gong v2/v3 mast is like 70 bucks and wings are out there on used marketplaces for pretty decent prices. But I’m looking forward to your self made wings! Looks like a very solid project.

[Odeer09]

Hi, Have you CNC cut a bent fuse for a gong mast before? Cheers

[DutchFoiler]

No I have not. But it wil be very expensive lots of cutting.

[newguy]

It turns out creating a quality carbon‑fiber part isn’t easy. I found Microsoft Copilot surprisingly helpful while researching how to make a carbon‑fiber mast. I decided not to laminate directly over a 3D print. Instead, I’m going to use the 3D print as a mold and vacuum‑bag the carbon fiber.