Core

I've begun to work on the actual "make a ski" part of this whole process.  I laminated the core out of redwood and pine, with walnut sidewalls..  I chose redwood because I had a nice long piece of it with very straight, vertical grain.  Since the grain was already very regular and vertical I didn't cut it into small strips and re-laminate it as many builders do.  The core is one piece of redwood about 4" wide.  On either side of that is pine, and finally on the outside is walnut.  Pine was chosen since it was on hand and has a nice light color.  Walnut was chosen for the sidewalls because it was on hand, it's stiff and hard (hopefully will make for good impact resistance), and it has a nice dark color.  I glued it all together with wood glue.

The first step was to glue together the redwood and pine.

Next step was cutting it out to the correct dimensions for the ski, minus 1/4" all around for the walnut sidewalls to be attached afterwards.  This allows the sidewalls to follow the sidecut of the ski.  To cut the core I had planned to create a 1:1 scale printout of my design, cut out a Masonite template to match that, and then use that temple to route the actual cores.  My plan was thwarted by the fact that I was unable to make a really satisfactory template.  So I decided to make a nifty jig based on the one used by Michael from 333skis.  After a lot of trial and error and frustration I was successful.

Basically it's a 2"x4" spine with 1/4" slots cut with a dado blade.

 In the slots go shims cut from Masonite to the dimensions of the skis (minus 1/4" on each side to account for the rails).  The rails are also made from Masonite.  In the slots go shims cut from Masonite to the dimensions of the skis (minus 1/4" on each side to account for the rails).  The rails are also made from Masonite.  The shims keep the rails from moving inward..  There are also 9 piece of threaded rod that keep the rails from shifting out.  To determine the lengths of the shims I first cut the middle and end shims based on the desired dimensions for the skis.  Then I tighten the bolt in the middle and allow the Masonite to curve naturally into an arc.  Then I measure at each of the other slots and make shims that just fit.

Then I screw down the core and run the router along the rails.

After the core is cut to the proper dimensions I glue on the walnut sidewalls.

Quiver

Line 5-0 90cm
Revel8 Revolt Chicken 105cm
Spruce 120 120cm (dad's)
Vokl P40 170cm (dad's)
New Ski Template 175cm
dimensions for the new ski are 136mm-101mm-136mm, quite similar to the Spruce 120s but lengthened.

And I've had some trouble with my bladder.  It had a hernia.  I think air from the valve hole leaked between the layers of the hose.  It inflated into a big lump, then a tiny hole popped in it to let the air leak out.  I thought it was going to explode violently so I watched from behind a door.  I was able to cut off the damaged part and reattach my hardware.  Not the end of the world.  The hernia happened while I was testing it at about 60psi.  I plan to press at 35-40psi.  After the repair I've left it for 3 or 4 days at 35psi and it has lost all of 2 or 3 psi.  Very acceptable in my opinion.

Here's a photo of the inside of high pressure discharge hose, if you're interested.  Just a bunch of nylon strings running 0 and 90 degrees.  The actual hole from the leak was actually quite small.  I cut it open to look inside. As you can see the outermost layer of the hose lifted away from the core of the hose making a bubble.

Fire hose and Profiling Jig. Nearing completion.

My fire hose arrived.  They sent me 12' instead of the 10' I ordered so I decided to make a baby size test piece.  I used 1" angle iron bolted together with 5/16" Grade 8 bolts to seal the ends.  For the valve I used a tire stem very similar to This one.  I got it from a local tire store who graciously gave to me for free. (Thanks Mr. Hill)  I also got some larger steel and rubber washers from the hardware store.

I installed the whole thing into my hose as shown:

Large steel washer and large rubber washer underneath hose.  The same reversed above the hose.  Above that the rubber washer that came on the tire stem and the steel washer that came with it.  On the top the nut.  Teflon tape on the threads of the stem.

The little hose held pressure decently, so I decided to move it up to the larger scale.  Unfortunately, when I inflated the big piece of the hose I discovered a hole almost exactly in the middle of it.  I called Heartland Pump (where I purchased the hose) and they were very helpful.  They sent out a new piece of hose that day (free) and I received it 2 days later.  This new piece hasn't leaked in the body at all.  It seems that air leaks out of the threads of the bolts clamping the ends of the hose.  I think some Teflon tape will solve this.  Other than that the hose is a success.

I have also completed the router bridge I will use to profile my cores.  I think my design is pretty original.  I combined several ideas I had seen on the skibuilders.com forums for adjustable planer cribs and adjustable router bridges and adjustable molds.  It has a plywood base with flat rails running the length of it.  The router rests in a crib that runs on these rails.  The router can move across the width of the crib, and the crib slides lengthwise along the rails.

Two pieces of MDF are screwed onto the plywood base.  They are only attached in the middle, however.

 At then ends I have T-Nuts hammered into the plywood base.  These have bolts that screw into them with a Phillips head.

  I drilled holes in the MDF to allow me to adjust them with a screwdriver without taking the MDF off.  By screwing them up I bend the MDF up at the ends.  The core then goes onto the MDF and is bent to match the curve of the MDF.  It will be held down with doublesided tape or screws on the waste portion of the wood.
This allows me to shape the core to be thinner at the ends and thicker at the middle.

And finally here's a picture of the almost complete press.

From top to bottom:
Top Beam
Top Mold
Fire hose
Cat Track
1/8" Masonite
Ski
1/4" Masonite
Bottom Mold
Bottom Beam

My latest purchases:
10' of 6" discharge hose: $45
4' of 1" angle iron: $8
10 5/16" Grade 8 Bolts and Nuts: $11
Rubber and Steel Washers: $1

Total thus far: $157
Final expected purchases:
Cordura wraps: ~$40?
Hopefully that's it, which would leave me at just under $200.

Cost of 1 pair of skis:
Everything but core and epoxy (skibuilders.com): ~$90+shipping
Core: Free (have wood already)
Epoxy: ~$20/ski? (not sure here)
Total: ~$130