First e-foil build

Build, Repair & Mod
1

I’ve decided I want to start a long term project of building an e-foil. I plan on using EPS foam and fiberglass for the board itself. Right now I’m just trying to figure out the general structure of the board and making sure it will be strong enough. I’m going to do most of the cutting of the foam with a hot wire cutter, I do have a CNC router that should be big enough to do some of the work though, like cutting out the area for the battery and electronics and whatever other smaller things I need. I also have a 3d printer that I can use for whatever it might be useful for for this build.

Does the structure I have here seem mechanically sound? I haven’t figured out how I want to seal the top off yet.

The shape is very basic because I’m purposefully modeling it to be a shape that can be easily obtained by using hot wire cuts etc. I will do some hand rounding of the sharp corners.

The board is 5ft long and 22in wide and the volume is 105L. I’m 205lb and 6’1". I’ve never done any kind of surfing or anything like this besides stand-up jet skiing, but I’m very athletic and learn fast. Is this volume too low for me to learn with, or will it just take longer? I’d rather have a board that is a bit harder to learn on and more fun to ride than one that is easy to learn with, but not very fun once I’m good at it.

Also, does anyone have any suggestions on where to order EPS foam online with reasonable prices and shipping cost? Or maybe somewhere local, I’m in southeastern MA.

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Welcome

Have a look at the board designs at Fliteboard or Lift to see shapes and volumes that you know will work.

Building a board with a waterproof hatch is not simple or easy compared to something like a surfboard.

There are statements here from very accomplished board builders who have chosen to buy a used Fliteboard rather than make their own.

Lots of info and helpful people here - keep reading😀

This is a spec sheet from Fliteboard that lists their board range and rider weight

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hi, I have the same configuration - height and weight, I also had no flying skill. my board is currently 180 cm by 80 cm and the second one is about 165 by 75-70 cm pvc. my opinion is that for training you need a large board in order not to focus, I will also advise a third fulcrum- good luck

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Can you explain what you mean?

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I HAVE A LEASH IN MY NOSE UNDER A BELT THAT CAN BE REMOVED AS WELL AS FOR CONVENIENCE.

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1 Like
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Thanks for the photo I understand now. :grinning:

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Thanks for the info guys. I think I might use the 2lb foam at https://www.foambymail.com/.

One other thing I’ve been thinking about is how to handle the motor wires going into the battery box and have everything be waterproof. I know that I could just run the wires through a hole and seal the hell out of everything with silicone sealant or something, but then the mast wouldn’t be removable without removing the glue.

Has anyone tried sealing shorter wires into the box that penetrate out the bottom of the board that have bullet connectors on the ends? The wires coming out of the mast could then be plugged into those to make everything removable.

I’m pretty sure that a somewhat tight fitting length of silicone tubing that is lubed up with silicone grease would be able to be slid over the connections to make them waterproof.