I built a E3 knockoff about 6 months ago. Built it a bit wider so I could use to learn to wing. Its 6’2"x24.5x6". 1.5 block foam w 6 oz E glass over 4.6 oz carbon, with additional carbon patches around foil box (bottom and deck). Standard closed cell foam ride engine type of track box routed in and glued in with west systems 404 (I think). The board is bomber, and likely a bit overbuilt. I noticed when I routed in my bottom handle (fcs without the vent) that there was some melted foam around the front of the foil box from the track box exotherm, and being in a hurry I did nothing about it.
Anyway when I whip into a wave the board literally starts squeaking when I pump. Sounds like someone having sex in the next bedroom. Pulled all the bolts, lubed the foil- still squeaking. Switched to my buddies board yesterday (same build and materials) and no noise. I can torque on the foil box like crazy with the mast and I can’t make it move at all, nor can I duplicate the creaking sound on land. Im thinking the closed cell foam box is moving slightly against that void.
My plan is to drill 4 pillars w a forstner bit through the deck to the track box, and another into the void. Then fill the holes with 2 part expanding foam 2lb. I would do multiple small pours to keep the exotherm down. This will give me closed cell foam attachment to the deck. Im going to skin that over and try the board again to see if that works. If not Ill have to cut the deck out and put stringers alongside the box and pour foam all that in. Im using stringers and standard boxes from now on. I dont like the standard box rectangle holding all that torque.
Thoughts? Kelly White
