Core Shots

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Well, I have a few of the early steps in building the PM Gear ski.

here's a core:

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A base with some doodles on it:

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Edges being bent to the base:

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Shaping sidewalls on the CNC:

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Guess I could have rotated that last one, in kind of a hurry, we have a lot to do tonight. Here's a shot of the CNC. It's a programable router table that shapes material to the thousandth of an inch:

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This is the computer that runs the CNC. You can't see the cuffs, but basically, I have chained Jim to the desk:

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Here's the glass that will wrap the core, actually that's happening right now. Gotta go!!!!!!!!!!!!!!!!!!

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Originally posted by homerjay
What type of wood are you using?

We're using fir cores now. We'll add maple stringers later.
But having a deadline forced us to go with straight fir, which has properties very similar to aspen and poplar. We had troubles getting some materials out of Europe. The setback forced us to streamline some aspects of construction. Because our primary mission at Hood is to test the sidecut for carving and edging on ice, packed, and glop (we already know this ski will kill in powder), we can add the maple stringers in production.

We had to make a lot of adjustments yesterday in the machinery to handle the core shaping and molds. Set us back a bit. But today will be the day. Funny how a deadline can really turn the heat up when you're doing something like this. I can't wait to get on the road.....

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EP - I expected someone would think that, but it's really not going to change the performance. Snap, camber stability,and flex are predominantly determined in shape, core thickness, and the glass wraps around the ski. Once we analyze how the sidecut works, compare the two flexes, and just ski it, the only thing that will change in the production model is that it will be made better based on testers' feedback.

We tested the NKOs in almost the exact same manner with regards to construction, tuning them up for the production run.
Because of the way resin penetrates and encases cores, core thickness and glass layers are equally or more influential in ski stiffness, flex, and snap than the type of wood used. So the difference between fir now and fir or aspen with a couple maple stringers in the production models will be almost negligible, according to the designer/builder.

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Glad to hear it, Tippster. I feel the same way x1000. Busy as hell, can hardly sleep. I said this week would be tense, but had no idea how much this has me worked up.

We wanted to do a foam core ski for phunk, but the shaving cream kept squeezing out in the press.

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Well, the first pair is getting pressed now. I feel like a new father sitting outside the delivery room. I had to leave the shop because I was going nuts. I thought I'd have them mounted by now, but it can't be rushed. I'm going to catch a nap and head back a little later to see the final product, get some shots, and try to get them posted tonite or in the morning.

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Originally posted by homerjay
Will you throw some cables on any of them so the pinhead crowd can test them?

Thanks for the updates, this is fascinating stuff.

Considering there are two pair; and considering the ratio of pinheads to fixed heel mags attending, to make such a sacrifice would severly limit the number of runs the majority would make, as well as the amount of feedback gleaned.

Are you gonna be there?

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Make that one pair. We did a soft version first, but it was too soft.
Looked like a million bucks, but too soft. I'll post pics tomorrow. Kinda bummed because we did a clear topsheet and a clear base. It's a see-through pair of skis. So now we will press some stiffies tomorrow and come back to the soft version when there's no Hood mini deadline to meet. We'll probably put a white topsheet on the stiffies because they were going to get white topsheets, which would have the graphic screened on it, anyway. Off to bed, back to the shop tomorrow. Looks like I'll be hitting camp late Friday night.....

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I might hang out and have the softs redone and shipped up, as well as some others.

Z - I told Justin. I think he's tied up working. Are you coming?

edit: too zoned to remember names

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Not at all discouraged our first pair coming out softer than we expected last night, we are forging ahead with another pair as I type. But to continue with the pics of the process, here's some from last night, leading up to and after the pressing..........

A shot of the base next to the core with sidewalls attached. Gives you an idea of what the 124-99-113 sidecut looks like.

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With the glass on and all the the component parts together, the skis head to the resin table.......

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Once resined, the skis go to the press and come out with a little extra glass hanging off the edges............

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An upright view before they get seperated...........

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It's a Boy!!!!!! No!! TWINS!!!!!!!!

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The excess glass gets trimmed off and wahlaa, the skis a ready to mount after a little base grind. The process has been repeated today and the next pair are now cooking in the press.

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When reverse stenciling the graphics, you have to mix ink with a very gooey epoxy. I originally made stencils from printer paper, but when I rolled over the paper, the stencil stuck to the roller. With time of the essence, I just grabbed a bush and started smearing our name on the base. As you can tell, I possess less than zero artistic ability.

edit: uhhh, brush

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Still working on them, taking a break. The stiffies took a little longer than expected. They will be done tonight, mounted in the morning, and on the hill at Hood Saturday morning. I was hoping to leave Tuesday or Wednesday. But the little things that came up along the way have made this the mad dash.

janus - edges are available in the US and Europe. We hooked up with a snowboard manufacturer for their knowledge, facilities, and mad skilz. The construction is quite similar to snowboards, but different in it's own ways. The equipment to make skis is virtually the same.

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Just got home after another late one. The stiffs are pretty stiff. Also think the softs stiffened up a bit sitting and curing the last 24 hours. So after a little curing on the stiffs, it might well be a measure of muscle to see who flexes them on the snow.

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Wow. Tyrone's stoked is so justified. If the skis looked a little on the homemade side in the shots posted to date, that perception will quickly fade when the finished products are seen - and skied.
We got a ski shop closed for summer to open just for the task of mounting these babies and the shop guys were so stoked just to get to mount them, they wouldn't charge for the job. I had to stuff $20 in each of their pockets for beer money. The head shop guy was like " bring in every mount and tune you have - it will be free - just throw me a pair of blems."

The skis are works of fukking art as you all will see from the Hood postings soon enough. I am officially on my way now.