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.
Hi Kelly,
Squeaking means she’s gonna break, very likely the noise is a fracture point that rubbing as you’ve figured out. Since you’ve checked the obvious culprit, could be the rails or top deck as they transfer the force from your feet to the mast.
Can relate, I make boards as well and also weigh a more than your avg foiler. One thing I did in my shop is make a mast mount to test out different box designs. Since you’re a DIY guy you could do the same in a couple of minutes. 2’x2’ piece of 3/4 plywood with a cross braced 1’ - 2x6 then I found some scrap metal and trimmed to the Lift dims. Works well and now I put all my new boards on it to test out before they hit the water.
Regarding repair… you got the skills, just make a new one, lol. donate it to your next DW buddy for the cost of materials. If you do want to try your luck I’ve found carbon top to bottom through the entire board to create an ibeam. Consider doing this for the entire with of your stance. Here is a DW, if you look close, you can see the lines of carbon running up from the box.
Good Luck!
Is the squeaking noise a sure fire signal that your boxes are getting close to failure?
I have a used dw board from a close buddy that does the exact same thing that the OP describes here. It had been a little while since I had taken it out in some swell energy and noticed it a lot today. Felt also like I had speed wobbles while dropping down a wave. Couldn’t tell if I was just at the top end or if the boxes are slowly giving way.
Sounds to me like your boxes are failing. Track boxes are the worst part of foil boards. Which is probably why people are pushing so hard for tuttle to come back. At least most board manufacturers have figured out how to properly install foil tracks now.
Damn. Yeah he said it squeaked the whole time he rode it and never thought much about it. Recently I tried another friend’s much bigger, spanny wing to try flat water pop ups, and noticed the squeaking much more after a couple of sessions on that.
Any idea how catastrophic these failures end up being usually? I assume still a low chance of losing my entire mast and wing if I continue to use it until failure? My hobby budget is somewhat depleted after a few wing purchases
Did you tie the boxes into the deck someway? Either by HD foam stringers, carbon rods, etc? If not what you are probably hearing is the foam under the boxes has been crushed from the pressure/force and there is a void inside your board.
Pic of my process have 2 1" thick vertical stringers going through the entire board so the strength is there. It is definitely overkill
It’s a KT Dragonfly Crossing, so just however KT built the board. I noticed today you can actually cause water to squirt out of a tiny seam at the front of the boxes between the plastic track and the carbon on top when you move the mast
Yeah I don’t think they have track boxes but 5 lateral ribs which the tracks are glued onto. I could be wrong about that model but have seen pics on Facebook of a KT board with tracks that have come out & that’s all what they were glued to. I was pretty surprised. hopefully this link might work.https://www.facebook.com/photo/?fbid=10161901406463640&set=pcb.1338350217225505&cft[0]=AZYsuykeK_tKTagdFTax3EtPZgl7udWp_5lf0nsl_DVVJvcb_Pw5U2CBmFcx0OVJxI_K8Q27E3qyvtETnwO-TU-MDQCKkCGqcFPYWkphoaepclvmCz3-AQyRF5qwlkrO79NX4RRA8F669n03WyVSERKJey2ZqQj0jUSbQBuweHtPIMInjop49YlJovswh3Ip6Do&tn=*b4H-R
Before you go opening up your board prematurely. I had a situation where I had squeaking on a self made custom board.. Took a video of it and every one said it was definitely the track boxes.
Turned out the mast had a high spot in the centre and even cranked down there was enough play such that it would rub between the board and the high spot.
See if you still get the squeaking with like an old shirt clamped between the mast and board surface.
