Last year, I built an external top-box foil assist unit, drawing a lot of inspiration and ideas from this fantastic forum. Most of my local riding friends are using Foil Drive Gen 2 systems and have built inset boards. While those setups have their strengths, I believe they still come with a number of limitations. That got me thinking — and sketching — about designing an internal foil assist system instead.
Over the winter months, I brought the concept to life. Now that the build is fully complete and tested, I thought it was time to share it with the awesome community here.
Build:
80x50x2mm aluminium section
12s3p battery with external balance charger
Matech V3 remote
ESC Sequire 12200 & Kontronic Jive 120hv
Flipsky 6374 motor
5ft3 board 19.5 inches wide with hatch at rear for assist access
The Housing Build:
• Constructed from a 620mm length of 80x20x2mm aluminium extrusion
• End Cap: Initially 3D printed, but due to flex and sealing issues, it was upgraded to a machined aluminium version with a silicone gasket for reliable waterproofing
• Motor Wiring: Plug and socket are integrated into the end of the housing, with cables routed internally through the board’s mast connector on the underside
• Finish: Experimented with home anodising for both the tube and end cap to improve surface hardness and resistance to the harsh saltwater environment.
@Strongarm I have 4mm carbon plates on top of aluminium section that has m8 large head nuts located in the plate. M8 studs then run down side of aluminium. Carbon plates give a super stiff connection. I’ll post some pics later
