Surfboard and method of construction
Disclosed is a surfboard ( 10 ) comprising a foam blank ( 10 ), rails ( 14 ) formed using carbon fiber materials ( 22 ) on the blank, and a fiberglass laminate enveloping the rails and blank. Alternatively, the blank and rails may be enveloped in a thermally active PVC or similar material.
1. A method of manufacturing a surfboard using a shaped surfboard blank having peripheral rails, a top side and an under side, the method applying carbon fiber material to substantially only the rails of the shaped surfboard blank and enveloping the carbon fiber applied rails and the shaped surfboard blank in a non-carbon fiber laminate, wherein each rail extends from the top side of the shaped surfboard blank to the under side of the shaped surfboard blank, each rail having one rail side extending from a periphery of the rail to the to under side of the shaped surfboard blank, said method comprising:
(i) adhering carbon fiber material having a unidirectional weave to substantially one side of one of the rails of the shaped surfboard blank, the weave being generally aligned with a longitudinal axis of the shaped surfboard blank;
(ii) laying fiberglass matting over the carbon fiber material;
(iii) applying resin to the laid fiberglass matting;
(iv) adhering carbon fiber material having a unidirectional weave to substantially the other side of the one rail, the weave being generally aligned with the longitudinal axis of the shaped surfboard blank,
(v) laying further fiberglass matting over the further carbon fiber material; and
(vi) applying resin to the laid further fiberglass matting.
2. A method of manufacturing a surfboard using a shaped surfboard blank having peripheral rails, a top side and an under side, the method applying carbon fiber material to substantially only the rails of the shaped surfboard blank and enveloping the carbon fiber applied rails and the shaped surfboard blank in a non-carbon fiber laminate, wherein each rail extends from the top side of the shaped surfboard blank to the under side of the shaped surfboard blank, each rail having one rail side extending from a periphery of the rail to the top side of the shaped surfboard blank, and another rail side extending from the periphery of the rail to the under side of the shaped surfboard blank, said method comprising:
(i) adhering carbon fiber material having a unidirectional weave to substantially one side of one of the rails of the shaped surfboard blank, the weave being generally aligned with a longitudinal axis of the shaped surfboard blank;
(ii) laying fiberglass matting over the carbon fiber material and over the corresponding one side of the shaped surfboard blank;
(iii) applying resin to the laid carbon fiber material and the fiberglass matting;
(iv) adhering further carbon fiber material having a unidirectional weave to substantially the other side of the one rail, the weave being generally aligned with the longitudinal axis of the shaped surfboard blank;
(v) laying further fiberglass matting over the further carbon fiber material and over the corresponding other side of the shaped surfboard blank; and
(vi) applying resin to the laid further carbon fiber material and the further fiberglass matting; wherein the method is repeated for the other of the rails.