Prone Foil Board Stiffness and Long Term Durability Building Techniques

Given the amount of pumping prone foilers have to do to connect waves, a stiff board that remains stiff is hugely important. Responsiveness is also directly affected by this.

Some older brands have been known for early board fatigue. I feel most builders are starting to figure this stuff out. Additionally, there’s the question of production boards vs custom boards. I’m suspect of both. I’m not sure what the custom builders are doing to keep their boards stiff. If any of you see this. I would love it if you commented. From what I can see, most are simply adding high density foam over the boxes to connect them to the deck. But is this enough? And in regards to production boards, I feel most aren’t stiff or durable enough, with the exception of a few brands.

Armstrong has their carbon stringers. I don’t think those go top to bottom though. I think they’re maybe at the top and at the bottom, but not fully connect the deck to the bottom of the board. Having said that, my Armstrong boards seem to remain stiffer for longer than others. That said, apart from the new X-form boards, they tend to be heavier than others.

Appletree would be at the top in terms of retaining stiffness. No question there. I think they would sell more boards if they worked on their prone shapes a little more and marketed them a bit better. Most of their focus right now is on parawing boards - understandably. But that’s a different topic. While they have a reputation of being heavy, the smaller boards, 45L and below actually tend to be lighter than others… because Appletree’s extra weight is in the foam. And the smaller boards have less of it.

I have an Amos Kruzer V2. So far after 20 sessions it still feels as stiff as day one. But that’s not a lot of sessions, so jury’s still out on durability. Not sure what he’s doing to reinforce boxes and prolong stiffness. I’ve been considering another in a different size, but I’m waiting on more time on this one to ensure long term durability. Mine has some deck pressures where I stand, like a surfboard, but that’s it so far. Not a dent anywhere else.

Sunova is another that I hear retains stiffness very well. Again, not sure what the secret is there.

As you can see, there’s a lot of brainstorming here and would love you guys’ thoughts. I’ve been looking at certain custom builders to have a 40L board made… but I’m concerned about stiffness durability, hence this post.

In the end, I feel that a combination of high density foam, carbon stringers, carbon boxes and extra layers of carbon back there, along with vacuum bagging (which should be the standard anyway) would be the way to go to make boards that retain stiffness.

Please let us all know your thoughts.

IMHO if you build a carbon structure with the loads taken by carbon then you can dispense with HD foam.
HD foam.is heavy and sucks at repeated load cycles.

I (try to) use carbon in its proper shape for the demand,Flat lams can take traction really well but they are poor with compression, where a tube or beam excels with far less material and weight.

Pics are from a box replacement i did a while ago, orig tracks were just embedded in HD foam … ;(

.Blue foam is XPS for waterproofness, xpse is 30kg/m3 vis HD Foam 80kg/m3.

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Aren’t epoxy boards stiff enough? I know in surfing they feel too stiff and don’t provide the usual rebound for pumping so they feel kind of weird.

I mean almost all prone boards in the history of foiling are epoxy and 99% of them are trash.

My secret is using a solid Divinycell blank(this is my secret sauce), internal carbon box reinforcement, and a 2x carbon wrap. I’ve got the stiffest toughest prone board on the planet but it’s a little heavy(irrelevant). Plus cause it’s all closed cell I can treat it like absolute garbage. I’ve got multiple dings and don’t really have to care about them.

I don’t think there will ever be real production boards built this well. On the manufacturing side it’s just too easy to piggyback on the far inferior surf industry construction and going this way you risk alienating alot of consumers coming from Surfing who speak that language.

Epoxy boards are stiff… yes. But then there are the special requirements of a foil board. The board has to be beyond stiff and retain that stiffness. We take it for granted, but just think about the amount of leverage we exert over such a small area of a board.

Sunova stands as my stiffest board yet which has no signs of fatigue, one of my Kruzers did get fatigue early on though, not complete failure just noticeable box fatigue.

The north VERT. is build like a brick. very stiff and responsive. I think they nailed it.
it fell off my car, and rolled down the carpark, only had a few scratches! If you get a chance, grab one to see. love that board. Im going to get someone to throw a riift track in mine.

I have to see some really good transparency around what is inside! Internal carbon reinforcement?

Ding resistance and stiffness are two different things. No point in the shell lasting 3 years if it’s not going to pump the same in 6 months!

from when I drilled it out for my FD signal. It was layer of carbon, HD foam, and another layer of carbon ( sandwitch?) then the EPS foam. im not a board builder. just talking from feels and compatinf to other boards I have ridden.
No idea how the tracks are installed or re-enforced. I have had this board for a good 2 years tow, prone and FD board. and from feel seems to be the same as when I got it new.

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I’ve looked at the Vert a few times. Maybe construction is great, I just don’t like the dims for me. 30L is way too small. And then 40L… that’s my preferred volume. But they made that one at 21" wide. Like, why so wide? 40L and and somewhere between 19"-20" is ideal.

Yeah, I do want a Sunova at some point. Been considering the Pilot or Pilot Mid around 39-44L. That said, the collab between Sunova and The Foil Shop looks pretty sick as well.

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