Forums Splitboards ISO – Jones Ultracraft 160
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  • #797552
    _ZakMills
    72 Posts

    I had an unfortunate crash that resulted in breaking half of my 160 jones ultra craft. The side that is broken is the heel side of the board for a regular footed rider. Any chance someone here had a similar situation and has a heel side ski to get rid of?

    #797767
    Scooby2
    612 Posts

    Earn’m,
    I can fix it with same materials and reasonably if you get the base ground after I’m done. Keep me in mind for a summer fix though, it’s happening here in the Wasatch this winter and I have a few boards to still get out.

    #797768
    vapor
    350 Posts

    Your the man Scooby,

    #808033
    Scooby2
    612 Posts

    This is a DIY but I’ll leave it here where the thread started. Ok, so after a false start I think I got this board repair headed in the right direction. The false start was that I vacuum bagged the first try instead of pressing and applied heat to fast. This caused the PTEX patch to expand and bubble off the boards core in the middle. So I earned some sanding. Steps to fixing a cracked split:

    In the photo below I made a template out of a sheet of alu. Tapering ends are important to remove a hinge point for the board to break on again. I clamp that to the base and cut into the ptex around the clamps, then clamp on the other side, move the first clamps and finish the cut. The left over fabric is some woven 5oz. carbon/innegra from the first try, it was really too thick for vacuum molding. Chisel the ptex off while not cutting into the base. Sand a taper into the remaining fabric, carbon in this case as this is an ultracraft.

    The patch should fit easily in the board. Remember that the patch will grow about one mm. when it gets heated up to cure the resin. It is best to cut the patch in a room that is 95 degrees or warmer so the sizing is close.

    Below are the fabric patches cut to give the board its strength back. I only use one patch with the fiber running across the board. I really like this material, it is a wafer thin 2.5 ounce unidirectional carbon with strands of Innegra to allow the carbon to flex farther before failure. The white part is the Innegra which is there to give the carbon more durability like fiberglass has but without the weight penalty. It is common in canoes, kayaks and surfboards and is beginning in the road bike industry. It will probably be pretty widespread in sports gear in a few years.

    Below I have 2 1/2″ pieces of plywood that have the same curve as the boards camber above and one piece of ply below the board. I have a clamp every 1.5 inches, maybe 16 of them turned pretty tight. I have a sheet of baking paper next to the ptex and a sheet of aluminum above that to carry heat to the resin. I heated this board to 105 for about 2 hours so as not to over heat and expand the patch before the resin hardened. Now in this pic I am heating to 130 F to cure the resin which adds toughness to the resin and increases its bond strength.

    This is the board base before grinding, It appears low and flat enough that the grind wont go through it this time, YAY! There is a little white line on the left where some of the innegra fibers are stuck in the crack between the old base and the patch, no biggie. It will be interesting to see if it stands the abuse that Zak can give it, he seems to ride a lot.

    What I didn’t show is that whatever fabric you use, you need to soak it in resin on a sheet of baking paper for a minute or two, then give it a hard scrape with a squeegee or spreader or plastic drywall knife to remove as much resin as possible. then lay the fabric in where you want it and squeegee as much resin off for each sheet. The warmer and more runny the resin the better. Too much resin will keep the base patch too high and actually weaken the composite. The core and base patch also need a coat of resin brushed on and any excess removed.

    #808034
    Scooby2
    612 Posts

    One more note: This repair and break was kind of unusual in that the board met a tree with a lot of force between the feet, so the base bent towards the rider and the base laminate failed in compression. It is a lot more common for a board to fail the other way, that is in compression on the deck side with the base composite still intact (or not sometimes, LOL JC!). This is an easier fix because you just sand through the deck. More importantly, you don’t have to finish it as well and you don’t have to get your laminates super thin like you do to get a ptex patch to lay in with close to the original thickness of the composite on the base, which is a bit of a trick with a lightweight designed carbon board.

    S2 fiberglass is an ideal repair fabric to repair a deck compression failure because it has much more compression strength than carbon. You could add one layer of unicarbon after sanding the main repair to make the repair black which looks better than a clear fix (or paint). This practice may become more common as superlight board weights get under 5lbs. (for a 160) and are costing well north of $1000.

    #808554
    moridinbg
    150 Posts

    Stellar job!

    I broke a Rossi XV in a similar way after hitting the pointy tip of a rock buried into the snow at full speed.
    The initial impact broke one board half in two and then proceeded to dig a groove all the way through the fiberglass:


    It broke the core and then broke the topsheet:

    All in all it was a huge impact. I was carrying an ABS backpack full of gear, clothes and stuff for a few days stay – probably around 15kg. It sent me cartwheeling, dislocated my shoulder, it was smelling of burned plastic after landing!

    In France everybody I talked to wrote it off and didn’t want to bother. I dried it as good as I could and then sealed it with epoxy. Next year I went back home, where with the help of a guy, who has his roots in building kiteboards fixed it like new. He has tons of experience repairing broken skis, snowboards and splitboards.
    I can’t find photos of the process, but here is the end result. I rode it pretty hard for the entire season and it still is in great shape!

    We approached it from the top. Cut a tapered piece off of the topsheet – taper is important, if it is perpendicular it will snap super easily, as noted by Scooby.
    We noticed the wooden core was snapped, so put “ribs” across the crack, then covered with layers of fiberglass and plastic to seal it on top (might have been ABS, but do not take my word on that). You can see the plastic has rubbed of from the Phantoms, after a season of riding, but the fiberglass is holding well:

    On the bottom just cut a piece of the base, cut a bit from the teared fiberglass, patched with a thin sheet of fiberglass and then filled with ptex + epoxy:

    On one of the photos you can see another decently sized gouge in the base. That one didn’t cut through to the fiberglass, so I have just filled it with regular PTex with a gun, but it’s a tad too big, so the ptex keeps cracking. The ptex+epoxy is essential for larger holes.

    P.S. The Rossi has a cheese-like ptex base, that dents just by looking too hard on it, but the wooden core is superb. It had soaked up significant amount of water before drying and sealing it, then spent the summer like that, but there was not a sign of rot.
    On the other hand, I broke the tail of a Never Summer Summit after a botched landing a few years ago. It had managed to completely rot a large swath of the core in the affected half in record time.
    I had it repaired in a different shop back then and it held well for about a season, before botching another landing and breaking again the same half, this time at the nose, instead of the tail.

    I also have a friend with a broken G3 Black Sheep and know of another one with a broken G3. All this boards – mine, the G3s have broken at the heelside half. Splitboards are definitely more fragile than solids!

    #808705
    Scooby2
    612 Posts

    Cool fix for some savage board damage. Glad you stayed above that rock. I like the wood ribs across where the core was split to carry new loads away from the old snap line. Thanks for the share, still waiting to get the fix I did back from getting ground.

    From what we’ve learned making superlight boards, my advice to anyone touring with a real light board especially the first few years of them, is to be pretty careful with it in split mode. It’s easy to design a split for how you want it to flex and be strong as a one piece, but when split all your weight bends out one half of that board. If you look at skis they are much thicker and stronger in the mid section than most mfg’s boards to handle all the riders weight on one ski. Splits can get some topside failures and small cracks often near the touring bracket and heel riser or just outside the binding areas. They are an easy fix when small and eventually they will blow up when riding hard.

    It’s hard to say one board’s wood core is more impervious to water. It might be the result of one laminate pulling away and leaving wood cells open to water when another failure peeled fiberglass off but left wood that was still solid with resin which would keep the water out.

    #811186
    Scooby2
    612 Posts

    Post grind on base side ultralight composite repair. Pretty smooth, a small bit of innegra showing but minor. Id put the last layer on innegra side down next time. I have a good feeling about this fix, we will see. Grind by 7even skis here in Utah, who I highly recommend.

    #811188
    Cbalke
    237 Posts

    Nice repair work @scooby2 !

    #811271
    downthemtn
    17 Posts

    Looks brand new! Excellent Job!

    #811418
    Taylor
    792 Posts

    The master at work.

    @sun_rocket

    #815872
    _ZakMills
    72 Posts

    Scooby did a 5 star job on this board repair. When I got it back it took a minute for me to remember where the damage was and even longer to see any evidence of him cutting into the board. It’s seen about 20 days of hard use since I got it back and she’s riding just as strong as ever. Well done sir!

    #815890
    Scooby2
    612 Posts

    That’s great to hear. I was just wondering about that fix yesterday. thanks for posting!

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