Frame to Planks

Part of the reason I undertook this project, was to learn some patience. It hasn't been easy. I wanted to ride this board the day it arrived. But, I've taken my time, done things the right way (within my ability), and it's paid off.

I have two cardinal rules so far. The obvious is measure innumerable times, cut/glue once. The other is, dry run every irreversible step.

I did a dry run with the frame and planks and I was glad I did. With the 90 degree weather, the glue set up time is about 15 minutes. The dry run helped me to set up my clamps and equipment so I didn't have to fuss with it. I also got to see how the parts fit together and where I needed additional shims.

I used ratchet straps across the strongbacks and it worked well. The straps were somewhat more convenient than the bar clamps. You just have to watch that the straps don't pull the keel out of alignment while ratcheting down.

My dad helped with the actual glue up. It would be hard to do this step without a partner. I clamped down the frames lightly and we verified that the keel was aligned and frames square. I tightened the clamps and re-verified. It got a little rushed at the end as the 5200 started to set in the heat.

One step I overlooked was having a tack rag on hand for clean up. It got messy. I got more 5200 on the planks than I would have liked, but it looked pretty good. I literally had to make myself leave the garage because I would have been there all night checking alignment and square.

Taking the clamps off and checking the alignment, I was very pleased. The keel is about 1/16" off center between frames 7 and 8, and frame 8 is about 1/8" out of square. I can probably account for most of this when I start putting down the rails. The important thing is, there was no major kinks and the keel and frames formed a good bond with the bottom planks. I couldn't have done it with out my Dad offering an extra set of eyes. I'm very proud of the way it looks. I have a bit of a mess to clean up, but the 5200 seems to come off relatively easy. Now, on to the rails.

Rocker Table

The first step in gluing the frame to the plank is setting up the rocker table. If you look on the indispensable forums like Tree to Sea and Swaylocks, you'll see some beautiful and complicated rocker tables. Grain Surfboards offers a custom set for each kit they sell as well. If you have the skill or the money (I have neither), then those are the way to go.

I opted for a much, much simpler version. Really all the rocker table has to do is support the frames during glue up. I shimmed under the rungs of the lamination table using scrap wood as recommended in the Grain manual. This is harder than it looks. Every time I got one frame to touch, it would push another out. I set up and dismantled the rocker table about three times. Eventually I just had to learn to live with well enough.

You can affix the shims to the rungs of the lamination table about any way you want. I tried tape first, but it is a huge pain. I picked up some stretch wrap which I found to be cheaper and far easier. It makes for a pretty solid hold as well.

I added additional shims conform the planks to the bottom contours built into the frame. The Seed has a subtle single to double concave from the belly through the tail. I dry fit the planks and frames to ensure it worked out and didn't put too much stress along the keel.

The rocker table looks ugly and it put my OCD into a frenzy, but I think it will work. Next step, frame to planks.......

Summer Hiatus

Well, a couple of things happened. Summer started, and my obsession with being in the ocean took over my daily routine. There was virtually no surf all summer, but the water was clear and in the mid-70's. I couldn't fathom locking myself in my garage with conditions like that, so my family and I spent most of our days at the beach.

Secondly, when I imagined how beautiful this board could be, I got a bit obsessed with perfection. However, I am far from a perfect woodworker. I froze and refused to put in any work for fear of screwing it up. But, I undertook this project knowing I would mistakes and learn from them. I got back into the garage, took a fresh look at the surfboard that had been sitting dormant since May, and put in some work.