I have made two pairs of skis so far and I use a vacuum press system with a metal cassette. For both pairs of skis, I have gone with a full cap instead of sidewalls. The issue I am having though is that both times so far the cap doesn't connect from the top FG layer and bottom FG layer in some spots, exposing the core. Has anyone had any experience with a full cap ski and could offer some advice?
Hi Josh, would be nice with a picture of the metal cassette and the setup and bit more info on the layup. Do you use topsheet?
Here are some photos which I hope help explains my process and issue. I do use a top sheet (.6mm oak veneer). In my ski I am currently using four layers of 8.7ox biax fiberglass and a birch core. Then the skis are layed up on the metal cassette and then the skis and cassette are placed into the vacuum bag. then using shims and clamps the camber/contact points/ tip and tail rise are created. in the first photo you can see the three wood runners under the skis and those represent the camber/tip/tail. The last photo is showing my issue with the cap separation.
Design looks nice, thank you for sharing!
I see you use vacuum press and wood veneer.
I have seen ppl do cap or channels on wakeboards, but with pneumatic press, not with vacuum, as it might not do enough pressure. I also think wood veneer makes it hard to be bent, I dont think you can bend wood 3D, especially without heat. I would my self try without the veneer on top first, then perhaps use thin topsheet plastic, or apply the veneer in separate step.
Yeah that seems to be the general consensus on the issue, that the vacuum just can't get the pressure really needed. I think I will look into how to get either full sidewalls or hybrid sidewall/cap for my next set.