DaySailer.org Forum

As promised, here some photos of the process I outlined above.

Board in pre-op 1.5/8" thick:
http://picasaweb.google.com/petemcminn/ ... 8683119570

Grooving to 1/4" depth:
http://picasaweb.google.com/petemcminn/ ... 4452923362

Skinning the old glass off:
http://picasaweb.google.com/petemcminn/ ... 1697563634

Planing down to depth:
http://picasaweb.google.com/petemcminn/ ... 6186844162

Shaping with sander:
http://picasaweb.google.com/petemcminn/ ... 9136517138

Rebuilding thickness with four layer of fiberglass cloth per side!:
http://picasaweb.google.com/petemcminn/ ... 4971092002

Final fairing layer with micro-balloon mix--looking at the leading edge, unfaired:
http://picasaweb.google.com/petemcminn/ ... 9330830386

Finished Board after final shaping and 3 coats 2-part polyurethane:
http://picasaweb.google.com/petemcminn/ ... 2280503362

The board ended up to be 1/4" thinner at it's thickest point (1.3/16"). Installed the board and went sailing yesterday. CB dropped without the slightest complaint.

Ahhhhhh!

Now for the custom handle!

nm