Dalton's Hull Build

Location
Wisconsin
Been working on this for 6 or 7 months now. Here we go...

After riding my squarenose for a season I decided it was time to see what these short hull are all about. With two weeks left before the ice froze over my goal was to make a short ski and see how it handled in the water.
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3.5 inches off the rear and I think 7 or 8 off the front. Not really important because it didn't stay this way long.

After test riding for a couple weeks the lakes froze and it was time to get to work. I decided that a stubby nose like the one I had didn't do much hydro dynamically for the ski with my riding style.
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The concept is to integrate a 4 inch rocker with a v shaped bow to give pop off waves while reducing drag when laid on its side in tight turns.

There's a long way to go from crudely shaped foam to a solid nose.
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Ignore the Watcon stickers as I have no affiliation. Here you can see the nose taking a solid shape with many layers of glass and several kinds of body fillers. This is easily one of the most time consuming stages.


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I took a short break from plug shaping and decided to make a new handlepole to complete my hull. Here we see a squarenose handlepole with an 8 inch section removed from the middle and the flare under the chinpad removed to follow a sleeker profile. Easier said than done considering the top section was about 1/2 inch narrower on each side than the bottom due to the taper in the original pole. An entirely new taper from base to handlebars had to be made and the curvature of the pole and top surface was altered. There isn't anything exactly squarenose about the pole besides where it mounts. The chinpad you see is a squarenose chinpad narrowed by 3 inches. It had already been used to plug a mold at the time this picture was taken. Just like the handlepole, the chinpad shares virtually no dimensions with any existing chinpad.

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Chinpad mold and new chinpad. Several version of the chinpad were made. This is the third chinpad mold I've made and most likely the last of this style.

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Here we have the handlepole plug secured to plastic sheeting in preparation for molding. Looking back at it I wish I had taken more time to create a sturdy mold. This handlepole was intended as a one off so I wasn't concerned about pulling more than one handlepole.

Time to get serious and buckle down on the build. With about a month and a half left before the Dell's Freeride my top deck still wasn't finished and no hull molds had been made yet.
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Chopped another 1.5 inches off the rear and and gave the corners a nice angle to make the hull feel even shorter when turning. Built the mold flange and ready for primer.

Garage looks like an angry explosive tornado zipped through...
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Location
Wisconsin
Gelcoat sprayed
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And bottom deck mold right after pulling from plug.
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About one month left to go and I have the final handlepole pulled from the mold and mocked up with my chinpad on the hull plug. You can see there were several changes to the nose design and the tray received a full rebuild.
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Took a break from plug shaping to make the bottom deck.
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Here we have the final bottom deck next to the first try that failed do to the epoxy gelling up in the pot. Lesson learned: Know your epoxy
The discoloration in deck on the right is just infusion mesh and Enkafusion stuck to the hull. It pulled out with some elbow grease.
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550/440

Maybe I'll get it all the way around NEXT time....
Location
Arizona!
Very cool build - looks like you progressed a long way in a short time frame. Subscribed.
 
Location
Wisconsin
Ten days left till the freeride. Bottom deck is done and top deck plug is prepped for molding.
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Gelcoat sprayed. I wish I had more incremental pictures but time was running short and I was in build mode rather than document mode.

Top deck had to be hand laid due to half my infusion epoxy being used up in the failed bottom deck. 5 days left to the freeride and the top deck is cured and sitting on the bottom deck.
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Only decent picture of the tray before paint assembly and turf. You can see a lot of the air bubbles left by having made it by hand.
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Primered
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Decks bonded, bulkhead installed, all inserts in and painted.
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Absolutely zero time for the meticulous body work. As such its pretty rough but prototypes aren't showpieces after all.
 
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Location
Wisconsin
The morning of the freeride I was frantically assembling the hull. By mid day I had the entire driveline installed minus waterbox and gas tank. Packed up all my remaining parts and turf and headed out with intention of completing it while there. Turns out I forgot hardware for the handlepole and steering system along with the fuel selector and filter. I ended up focusing on riding and having fun and decided to finish the hull when I got home.

Needless to say it was completed the following monday. Final bare hull weight was 66 pounds. Bottom deck weighs 32 and top deck weighs 24 if I recall correctly. That leaves ten pounds in plumbing, inserts, etc. Seems a bit high to me...maybe my scale was off for the final weight.

Anyways I have some action shots from the test ride.
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Takin a break
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I still need to make a hood so I suppose this is still a work in progress. I learned a lot from this hull build and will be putting the lessons learned towards the next, even more ambitious build.
 
Location
Wisconsin
Thanks for the compliments guys. A few people have asked questions about my avatar pictures the last couple months and I finally decided it was time to make a build thread.
 
Location
Wisconsin
Only if you bring that fancy new hull you're building!

Anyone on the fence about getting a light(er) hull should definitely do it. I couldn't believe what a difference it made even with a tired old 650.
 

Byeai

"Cheetos-Man"
Location
Melbourne FL
Dude when I opened this thread up and saw a sn I was like oh stock hull build then I saw the stock Pole mold and was like ughhh ok and then bottom mold going and was like ok I like this build now and then the end result it a pretty crazy looking ski that looks fun nice job man keep it going dude looks awesome

Sent from my SAMSUNG-SGH-I337 using Tapatalk
 

Sanoman

AbouttoKrash
Location
NE Tenn
Dude when I opened this thread up and saw a sn I was like oh stock hull build then I saw the stock Pole mold and was like ughhh ok and then bottom mold going and was like ok I like this build now and then the end result it a pretty crazy looking ski that looks fun nice job man keep it going dude looks awesome

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Thought the same thing and WOW!
Nice work
 

CRJ

Hibernating
Location
Toronto
nice build! where in wisconsin are you? im headed up to wausau in aug/sept. ill be bringing my BB square.
 
Location
Wisconsin
Dude when I opened this thread up and saw a sn I was like oh stock hull build then I saw the stock Pole mold and was like ughhh ok and then bottom mold going and was like ok I like this build now and then the end result it a pretty crazy looking ski that looks fun nice job man keep it going dude looks awesome

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Haha thanks man. I agree the handlepole and hull build didn't look promising from the start. I don't think I could have done the handlepole without the experience from shaping the hull plug and I certainly could not have made the hull molds without having made so many chinpad and handlepole molds. Definitely not a beginner's job. There's just so much to go wrong during making a mold of that size. I couldn't believe I got it first shot.

CRJ, I'm in the Waukesha area if you know where that is. Maybe we can set up a ride with some other members when you are in the area.
 
I don't think I could have done the handlepole without the experience from shaping the hull plug and I certainly could not have made the hull molds without having made so many chinpad and handlepole molds. Definitely not a beginner's job. There's just so much to go wrong during making a mold of that size. I couldn't believe I got it first shot.

This is so true. I've been bouncing ideas off Dalton and he's been a huge help on my build. I have to say, I have so much more respect for people that design and build hulls now. Dalton makes it look so effortless in this write up, but there is so much going on that isn't documented and that's where so much of the time is spent. Again, huge kudos to you. It looks awesome and I can't wait to take it for a spin one of these days.

I travel up to the Chicago area every 3-4 months. I will have take a few extra days and make the trip up to Waukesha next time.


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CRJ

Hibernating
Location
Toronto
yea id be game. ill try to remember closer to the date
 
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