RETRO FISH TOA 5'6" - FINAL SMOOTHING 1 of 2

RETRO FISH TOA 5'6" - SHAPING RAILS 2 of 2

RETRO FISH TOA 5'6" - BUILDING TAIL 1 - 2

RETRO FISH TOA 5'6" - BUILDING NOSE 1 of 2

BUILDING NOSE 1 of 2 (Work time – 1 h for wood block and 2 h for shaping )

The nose will be built using three layer of balsa and two of mahogany.

1^st and 2^nd block glued

nose paper template will give final shape 

After initial rasping

…and sanding

…almost finished..!

RETRO FISH TOA 5'6" - THE ITALIAN JOB

Saturday, one of the most important HWS website has dedicated an article to TOA !!

Don’t You believe it?

See now our page “ARTICLES” or click directly on www.woodensurfboards.blogspot.com  

Thanks again Grant !

RETRO FISH TOA 5'6" - SHAPING RAILS 1 of 2

SHAPING RAILS 1 of 2 (Work time – 3-4 h each side)

After gluing all layers it’s time to progress to one of the most important part of the board…the rail shape is closely related to the performance and manoeuvrability.

For this step is fundamental to follow strictly the design and to have in mind exactly the building procedure.

In summary we have take 6(six) section each 30cm and using CAD we have drawn for each section 3 triangles corresponding to the material to remove. After having marked the sections on the board we started to mark one point on deck and one on side corresponding to the hypotenuse of the first triangle.

To link all the points of the deck making a line and the same for the side.

Now…rasp away the triangle for all length.

A lot of work but it’ s amazing to see more and more the board take shape.

.... following pics shown our method: 

Take away extra material 

Six sections 

A long splint is very useful to link all points

Rail marked and ready for rasping 

First step completed

RETRO FISH TOA 5'6" - BUILDING RAILS

BUILDING RAILS (Work time – 30 min + 24 h glue drying time each layer !)

Finally we start building rails…!

We have to glue two layers of Samba plywood and five layers of cork, total 30mm thickness each side.

At this stage the board is ready for building rails

First samba layer has to be drilled to save weight

Protect bottom & deck with paper and to glue first layer using big elastics and some weight to maintain desired shape during dry time (24 H)

First layer and pressing technique

First layer and pressing technique

Remove as material as possible to the first layer

Apply glue to the first layer

Second layer pressed with the same pressing technique

Once glued remove extra wood 

Lay down roll of cork on each side to take the template to cut off, after to apply glue and press it waiting 24 H for drying. Repeat the sequence for each cork layer.

Cork cutting operation

First cork layer glued and clamped

RETRO FISH TOA 5'6 - INTERNAL BLOCKS FOR FCS FINS AND LEASH

FCS internal blocks for fins & leash (Work time – 1 hour + 24 h glue drying time)

Now It’s time to glue in all the backing blocks for the fins and leash plugs.

In order top save time and money we have used reject of samba plywood to glue each other.

surface preparation before gluying blocks

Gluying of the fin blocks in place

internal fin blocks top view 

Gluying of the leash block in place

RETRO FISH TOA 5'6" - INTERNAL TAIL AND NOSE PREPARATION

Internal Tail & Nose PREPARATION (Work time – 2 hours + 24 h glue drying time)

Internal tail & nose reinforcements shall be shaped to match bottom curves and internal rail splints.

Its necessary to use paper template (extract to design) for positioning correctly of al splints.

Once the glue is dried use rasp for obtain the desired shape.

alignment phase on the actual shape using paper template

preparation & gluying of internal nose reinforcements

UP: gluying of int. tail reinforcements DOWN:alignment and Gluying of upper int rail reinforcements

before & after wood carving

fish tail takes shape..!

RETRO FISH TOA 5'6" - INTERNAL RAIL PREPARATION

Internal Rail Preparation (Work time – 2 hours)

Once the bottom and deck plywood are glued it’s time to prepare lateral sides for rails attachment. 

to smooth with a plane

to check first layer interface

Rails attachment wil be done in a second stage after installation of internal tail & nose reinforcements

RETRO FISH TOA 5'6" - TO GLUE DECK PLYWOOD

To glue Deck Plywood (Work time – 1 hours + 24 h glue drying time)

cover rails with paper Scotch tape

domed deck look pretty good!

RETRO FISH TOA 5'6" - TO GLUE BOTTOM PLYWOOD

To Glue Bottom Plywood (Work time – 1 ½ hours + 24 h glue drying time)

Once the fishbone is ready, internal struct. can be glued to the bottom plywood:

_ Lay down frames/Spine on bottom to mark out position on it using pencil

_ Place marked bottom plywood on the ART

_ Lay the polyurethane wood glue between mark lines in way of structure

_ press internal structure on bottom plywood using cross bar

_ wait for 24 h for drying glue time

Glue the frame to the bottom planks using the rocker table

Pressing the skin into the frame

Frame is now attached to the bottom planks