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Dlonetti
August, 2024

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Anybody making skis?

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ChaseingSkiing
Posts: 14 - Karma: 156
Has anyone ever built there own ski on here?
Jul 11 2024 9:41PM
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-eREKTion-
Posts: 1554 - Karma: 10,248
@iggyskier @hot.pocket
Jul 11 2024 9:53PM
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weastcoat
Posts: 6307 - Karma: 72,505
There
Jul 12 2024 8:12AM
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FaunaSkis
Posts: 605 - Karma: 6,567
There used to be an active thread of ski builders, and it’s where I came up, with the help of the likes of @loganimlach.

there also used to be a how-to on building skis at skibuilders.com, along with an active forum (which is still functional)
an attempt to link to the how-to: https://web.archive.org/web/20081220022230/http://skibuilders.com/howto/

having gone through it all (admittedly in Europe, not the US) I’m happy to answer questions on getting into it.
Jul 14 2024 8:29AM
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1spliff2guinnies
Posts: 657 - Karma: 1,983
Is it possible to afford all this equipment in today's economy?
Jul 16 2024 2:51PM
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FaunaSkis
Posts: 605 - Karma: 6,567
1spliff2guinniesIs it possible to afford all this equipment in today's economy?


A basic construction ski; hobbyist vacuum pump set up & vacuum consumables; CNC cut mdf female mould, core & base; aluminium mould lining sheet; and basic joinery power tools to finish them would probably cost ~€1500/$1600, which is about 50% more than I spent on my first skis all in. Biggest increase would probably be down to the cost of the CNC work.
Jul 16 2024 3:36PM
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JFU
Posts: 50 - Karma: 503
FaunaSkisA basic construction ski; hobbyist vacuum pump set up & vacuum consumables

Instead of using a pneumatic press, could you use a hydraulic press?

I suppose it is easier to get more consistent results using a pneumatic.
Jul 18 2024 10:20PM
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FaunaSkis
Posts: 605 - Karma: 6,567
JFUInstead of using a pneumatic press, could you use a hydraulic press?

I suppose it is easier to get more consistent results using a pneumatic.


For a starter set up for somebody without much experience in these kind of projects, I would definitely suggest vacuum, you get less pressure but its cheapest and easiest to get going with a small composites pump, a vac bag set up and a rocker line (female) mould.
If you're committing to producing more and or have experience with/access to a suitable higher pressure set up, you'll get better results with pneumatic or hydraulic set ups, it will just take more work to get it going.

The advantage of an air based system, either vacuum or pneumatic, any leak won't cause a mess.

My route was to develop my ideas with a simple vacuum set up and then when I went to expand and produce, I found an existing factory to make them rather than develop my own production set up further. This was due to my lack of experience building or even using these kind of systems and not knowing anybody who did, and my desire to get going quicker.
Jul 19 2024 6:33AM
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JFU
Posts: 50 - Karma: 503
FaunaSkisFor a starter set up for somebody without much experience in these kind of projects, I would definitely suggest vacuum, you get less pressure but its cheapest and easiest to get going with a small composites pump, a vac bag set up and a rocker line (female) mould.
If you're committing to producing more and or have experience with/access to a suitable higher pressure set up, you'll get better results with pneumatic or hydraulic set ups, it will just take more work to get it going.

The advantage of an air based system, either vacuum or pneumatic, any leak won't cause a mess.

My route was to develop my ideas with a simple vacuum set up and then when I went to expand and produce, I found an existing factory to make them rather than develop my own production set up further. This was due to my lack of experience building or even using these kind of systems and not knowing anybody who did, and my desire to get going quicker.


I know from boat manufacturing that a vacuum setup to pull the epoxy throughout the entire fibreglass layout is seen to be better. A light product with the same strength but you produce less weight.


I would of thought that it would be the more costly. You can find a 10ton press for like 300aud which is pretty cheap imo, but as you stated, the leaks can be very messy especially with the cheaper ones.

Will you continue with the vacuum setup for the future? Or have you thought about changing the way you press skis?
Jul 19 2024 7:25AM
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JFU
Posts: 50 - Karma: 503
JFUI know from boat manufacturing that a vacuum setup to pull the epoxy throughout the entire fibre layout is seen to be better. A light product with the same strength but you produce less weight.

less waste*
Jul 19 2024 7:40AM
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FaunaSkis
Posts: 605 - Karma: 6,567
JFUI know from boat manufacturing that a vacuum setup to pull the epoxy throughout the entire fibreglass layout is seen to be better. A light product with the same strength but you produce less weight.


I would of thought that it would be the more costly. You can find a 10ton press for like 300aud which is pretty cheap imo, but as you stated, the leaks can be very messy especially with the cheaper ones.

Will you continue with the vacuum setup for the future? Or have you thought about changing the way you press skis?


Are you talking about a vacuum resin infusion set up? That's not what I'm suggesting for a starter set up.
What I'm suggesting is wet layup, pressed into shape with vacuum pressure.
So wet out the fabric and spread resin across the non-fabric layers, seal off the laminate with a vac sheet to the mould lining, use a small vac pump to draw out the air, putting pressure on the laminate with the vac bag, pushing into the rocker line shape, heating the laminate with heat blankets and leaving it to cure. Rather than pull through the epoxy.

I'm sure you can find hydraulic presses for cheap, its finding one big enough, getting it to you and having the space for it that could be difficult, whereas you can get the vacuum pump set up off the shelf and all you need is a few metres of clear worktop. Makes it more accessible to those starting out.

I'm going to develop my in house set up, likely to pneumatic, to improve the quality & consistency of my prototypes but, with it relatively cheap to alter tooling and produce samples with the factory, there's not a lot of need.
Jul 19 2024 9:17AM
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JFU
Posts: 50 - Karma: 503
FaunaSkisAre you talking about a vacuum resin infusion set up? That's not what I'm suggesting for a starter set up.
What I'm suggesting is wet layup, pressed into shape with vacuum pressure.
So wet out the fabric and spread resin across the non-fabric layers, seal off the laminate with a vac sheet to the mould lining, use a small vac pump to draw out the air, putting pressure on the laminate with the vac bag, pushing into the rocker line shape, heating the laminate with heat blankets and leaving it to cure. Rather than pull through the epoxy.

I'm sure you can find hydraulic presses for cheap, its finding one big enough, getting it to you and having the space for it that could be difficult, whereas you can get the vacuum pump set up off the shelf and all you need is a few metres of clear worktop. Makes it more accessible to those starting out.

I'm going to develop my in house set up, likely to pneumatic, to improve the quality & consistency of my prototypes but, with it relatively cheap to alter tooling and produce samples with the factory, there's not a lot of need.

Ahhh, yeah I was talking about a resin infusion setup. I gotchu now.

Yeah I can see how a vacuum setup is easier and more cost effective when starting out.

I reckon you are right with heading towards pneumatic setup for the future.

Are you building skis from a hobby perspective or a business perspective?
Jul 19 2024 9:46PM
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maaattt
Posts: 2397 - Karma: 29,229
Yes
Jul 22 2024 1:04AM
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PartyBullshiit
Posts: 3217 - Karma: 16,446
JFUAhhh, yeah I was talking about a resin infusion setup. I gotchu now.

Yeah I can see how a vacuum setup is easier and more cost effective when starting out.

I reckon you are right with heading towards pneumatic setup for the future.

Are you building skis from a hobby perspective or a business perspective?

https://faunaskis.com
Jul 22 2024 2:54AM
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snowfinder
Posts: 2789 - Karma: 33,623
https://www.vacupress.com/
Jul 22 2024 11:04AM
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1spliff2guinnies
Posts: 657 - Karma: 1,983
I'm really interested in the pre-production stuff that people do? What kind of planning is involved; how do you translate the ideas into a prototype? I think that's truly where the magic happens. Or do you just throw spaghetti at the wall and see what sticks?
@FaunaSkis
Jul 22 2024 2:46PM
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snowfinder
Posts: 2789 - Karma: 33,623
1spliff2guinniesI'm really interested in the pre-production stuff that people do? What kind of planning is involved; how do you translate the ideas into a prototype? I think that's truly where the magic happens. Or do you just throw spaghetti at the wall and see what sticks?
@FaunaSkis


Cad programs are a good place to start, look up snoCAD-X if you dont know how to use a program it's very user friendly. Also go here
http://www.skibuilders.com/phpBB2/
Jul 22 2024 3:02PM
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JFU
Posts: 50 - Karma: 503
PartyBullshiithttps://faunaskis.com


I know he sells skis but is it more of a side gig for fun, or not. You get me?
Jul 23 2024 3:37AM
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PartyBullshiit
Posts: 3217 - Karma: 16,446
JFUI know he sells skis but is it more of a side gig for fun, or not. You get me?


Well they’re a legit company so I don’t think it’s a side gig being made out of his house if that’s what you mean
Jul 23 2024 12:18PM
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FaunaSkis
Posts: 605 - Karma: 6,567
1spliff2guinniesI'm really interested in the pre-production stuff that people do? What kind of planning is involved; how do you translate the ideas into a prototype? I think that's truly where the magic happens. Or do you just throw spaghetti at the wall and see what sticks?
@FaunaSkis

In the early days of my designs I demo'd a lot of skis, trying out all sorts of shapes and constructions, to give me a sense of what design elements I liked and how you get that ski feel from the construction & shape. That combined with a good video series 4frnt did called tech talk which broke down the key design elements and explained things like extruded vs sintered bases.
My first pair were still something of a shot in the dark, with using their standard materials (wood core, triax glass etc) from the German ski building supplier. Junk supply now have a design tool which can be useful. After that, you get a sense of glass/carbon weight, wood stiffness etc. saving some trial and error.
JFUI know he sells skis but is it more of a side gig for fun, or not. You get me?

I still have a day job while I build the business, which helps with boring life things like getting a mortgage, credit etc. I've plans for the future to take it full-time once the business is big enough and sustainable.
PartyBullshiitWell they’re a legit company so I don’t think it’s a side gig being made out of his house if that’s what you mean

All the production skis are made in a Czech ski & wakeboard factory and so come with warranties and high production quality. Handbuilding skis myself is just for testing ideas now, before they go to the factory for sampling & production.
Jul 25 2024 10:08AM
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