I don't keep track, its 20-30 minutes every time I work on it. I sand and shape for 15 minutes then lay down some glass. I use a 3:1 epoxy so I try to prep just enough area to use 4 oz of epoxy which isn't much. I always do the first layer with a thin tape to make sure there are no air bubbles and then ill do 2 layers wet of heavy fabric twice over the top of that.
I don't really have much of a plan on paper, so I just look at it when I get out there and start working, so I've had to re do multiple areas or scrap ideas halfway through a few times. If I had to guess I'd say maybe 80 hours so far.
It weighs 40-50 right now with no pole, hood, or pump. I didn't weigh it before but I cut about 15lb off of it.
I'm glad you are curious about the process, I always have been but noone really posts the little details and steps of the process that seem boring and insignificant, but the truth is this whole process is just a ton of baby steps, and you don't have to be a pro to do it. All you need is the guys to chop up your ski, a little general knowledge of epoxy and fiberglass, a lot of sandpaper, and the ability to function with tiny shards of glass in your hands and arms everyday lol.
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