Please do some reading and searching on this forum. You will find a lot of information on this subject, and information on more complex issues you will face while building your DIY board.
I hate to say it, but there is no way around the 5+ days of reading time needed to wrap your head around everything. You’ll see your read time under your stats. You’re currently at 27 minutes.
Please get some time in reading, and researching your build. Once you know what you want out of your board, we’ll be here to help!
As FJ said, reading time is your best friend.
However, learning how to (ab)use the search function should be your primary skill, with keywords like 80100 or 63100 or 6384 which all are outrunner motors requiring modifications
Actually been here for 2 years but lost access to old email account. I see they are seals but I can’t figure out how to build with sss 56104 motor. I just recently got back into trying to build a foil again so figured I can try again but ask for help this time.!
Its alright i will just try the stuff I use for drone and esc, and remotes.
Before you judge someone by ranking maybe you should ask.
I plan to build a similar box. However, I ask myself how the junction between the mast plate and the hole on the picture will be done ? Do you have tips for me ? in order to be watertight
We finished “building” the 2300 cm² universal wing with the hollow aluminium mast some time ago, and are looking forward of testing it this summer.
The plan is to be able to foil as slow as possible as the max speed here on my home lake is only 9km/h
The foil attachment area core is high density foam. The strength comes from the carbon fiber. The area where the mast plate sits is layer much thicker for strength. The force is compression. So a wood core, or high density foam, or Carbon tubes, or something is needed internally to prevent the core from crushing.
The holes most obvious function is for the wires to pass through. But, the holes more important function is structurally connecting the bottom layer of Carbon fiber to the layer of carbon fiber on the top (bottom of the battery box). This prevents delamination. Nothing tricky. Just cut the hole and carbon fiber or fiberglass it.
The fasteners are flange nut type, sandwiched in the lamination process.
The battery compartment lid doesn’t need to be concaved. My buddy helped me build this board and he had a CNC, so it was easy to do that and it saved some weight.
Hope this made since. Still working on my coffee this morning… yawn
Did you make any progress with your build? I didn’t mean to shut you down. I suggest using the 65161 motor and filling it with…yes, you guessed it! CorrosionX!
Hi Flightjunkie, what a professional looking board!
What are the dimensions (L x W x H) of the hd foam for the foil mount. Did you use pour foam or glue a machined block? Is there any glass/ carbon between LD and HD foam? What is the thickness of the LD foam above HD foam, and why did you not have HD foam all the way to the bottom of the box? Many thanks!
The HD foam was just cut from a block. The HD foam is only needed where the mast bolts to the board. Otherwise the forces will compress the foam core. The HD foam replaced the other foam in this area and is sandwiched between the Carbon fiber on the bottom of the board and the carbon fiber on top (bottom of battery box).
The other dimensions you asked about aren’t important. Size it as needed for your board.
Thanks for the reply. So if I use the nut plate nuts with depth 10mm, I would add a HD foam section with 10mm thickness just bigger that the mast mount contact area? Would this have enough strength with 3 layers of 6oz/200gram 2x2 twill cf on each side? I am just trying to make sure my foil mount is strong enough.
I would say the bottom of the battery box. Bottom of your board. Where the foil mounts. Sould be at least 1" thick HD foam core. Yes. 3 layers of 6OZ carbon on both sides should be plenty strong. Just make sure the hole is glassed. Because this structurally bonds the top and bottom laminate together. If you don’t glass the hole, the bottom layer will probably delaminate under the loads.
Yea. It just looks heavy! I’d try for a lighter weight option if I was you.
You just have to make sure there is a layer of fiberglass or carbon fiber cloth under the aluminum so it is encapsulated / bonded to the skin if that makes sense. Otherwise it will get smashed down into the foam over time and endup breaking loose from the surface bond with the skin of the board.
Hi @Flightjunkie,
Did you used a flipsky 65161 motor for this build ?
(I don’t think to have seen the answer on this thread, but in case you already answered that, I’m sorry to disturb you).
