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 Post subject: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Tue Dec 09, 2008 10:00 am 
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Joined: Wed Nov 19, 2008 5:20 pm
Posts: 12
So, I figure your first post should be a long one... and it was endorsed by BCrider.

So, first off... I'm a telemarker :banghead: so get over it. But my wife and most friends board, so I'm a surrogate for them.

I’ve mounted many a tele-binding and alpine binding in my life (OK, several). I used to think you needed time, care, and patience, and some skill in doing that. Well, yes you need care and patience, but time and skill are out the window. Any drunk monkey with a drill and some epoxy can install telemark bindings after trying to build a splitboard.

Not that any will care, but I thought it was important and healing to photo-essay this process. I actually found it fascinating. And I would have sure preferred a photo-guide versus text and sketches.

So.... here is my TR, and the formative story of a boy becoming a man... of a home handyman becoming a contractor, of an idiot becoming a genius. I could go on.

Anyway, I know most of you are snowboarders, but I offer condolences to my poor friends that have chosen the unfortunate path of the single plank. :wink: Thus, I felt it was necessary to take it upon myself to liberate the single-planker wankers and show them the joy of easy backcountry movement. Well, ok, I also wanted to get my wife off the snowshoes, but didn’t have the budget for a ‘proper’ splitboard.

So, I have chosen her and her older Jennyus Tara Dakides pro model board as the tool of her liberation. This is the story.

It started with one of those generous discount codes from the very kind Dave and Autumn at Mammoth Mountaineering Supply in Mammoth, CA. I got the goods delivered at a great price (unavailable in the Vancouver marketplace).

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From there, it was time to start the task. I was a bundle of nerves. Shaky, dillusional, sweaty, and highly in doubt of my abilities. Time to get started...

Here’s the official package opening event:

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That’s intimidation. Just a box o’ bolts, plates, and 4 pages of instructions. Note to self... put beer away and focus focus focus.
I chose to do this TR, as the instructions are clear, but not fully complete in terms of specialised details that can only come from working on skis/boards and other basic handyman skills. Let’s go!

Time to pull out the board and celebrate its last days in a ‘whole’ configuration. 2005 Jeenyus Tara Dakides Pro 149cm with unicore wood core construction and Forum ETA bindings. Fresh coat of unscraped wax to protect the base from epoxy, shavings, and other debris (not in the instructions, but always smart).

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Step 1: Mark centre of board along base. Measure 4,372 times, cut once (something oddly fun about slicing a happy face down the middle):

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Step 2: Cut through toe and heel edge with a hacksaw (not in instructions, and thanks BCRider) so you don’t delam or blow apart the edges with the circular saw:

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Step 3: Tape the topsheet along the centre line, as you will saw with the base up and want to keep the topsheet from chipping (not in instructions):

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Step 4: Tools of the trade – don’t forget the goggles (beer goggles?):

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Post cut satisfaction:

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Step 5: Clean the sawdust and residue thoroughly. Now take a block and fine sandpaper (I used 80 grit, then 120 grit) to flat sand the new exposed edge, and a flat file to file the edge of the exposed base to 45 degrees to allow the board to come as tightly together as possible (I actually abandoned the file and used a bench grinder with a fine wheel, as I have descent control on the bench grinder):

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Step 6: Paint or spray on an exterior enamel, varnish, or varathane. I went with 4 coats of clear enamel over 2 hours:

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Step 7: Installing the pivoting hooks – this is what will hold the board together and align it – use the attached templates. They are stickers that will also help pull the board together, however, I used other stickers to hold the board, so that I could save and re-use the templates, as I see this splitkit totally reusable on future boards. Centre punch (or Philips-punch) the drill crosshairs:

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Magic with a 3/16” bit:

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Countersinking the hex/alan bolts base-side style – note slow cure marine epoxy around the bolt heads to seal the base and hole (not in instructions – weird, huh?):

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Voila! Or Voile! Pivoting hooks:

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Now it’s gonna’ get scary – and sometimes sketchy...

Step 8: Mounting the Touring Bracket and climbing bar is an exercise in boldness, as we’re about to rip the crap outta’ the base and inflict some serious impact. So, make sure you get the template set well after finding the balance point of the board and centre punch the three ¼” pilot holes, then drill the pilots from the topsheet through to the base:

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Now flip the board, and grab a ¾” wood bit and set your countersink holes for the t-nuts – YIKES. I drilled just to the base/core interface to ensure a flush finish:

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T-nuts ready to go:

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Pound T-nuts into the base with a hammer – c’mon this is not the time to be shy.

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Fill any gaps and seal the exposed base completely to prevent water damage with slow cure marine epoxy (again, not in the instructions – so you’re supposed to just expose the core????):

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The final touring bracket installation – whew! Now repeat for ski... umm... board #2:

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Step 9: From the template and centre-punch work in Step 8, it’s time to drill the two pilot holes for the climbing bar... same process as Step 8.

Here is a rather clean and simple application of a climbing bar (although I might have preferred to see a taller climbing post and don’t actually know why you have to drill through and t-nut given there is no torque or twist on the climbing bar – seems a standard 9/64” binding wood screw wood suffice):

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The finished base with counter-sunk and epoxied touring bracket and climbing bar installation:

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Step 10: Mounting Track Blocks is pretty straight forward, as long as you’ve remembered your stance angles for rear and forward foot and remember if you’re regular or goofy foot. This is the most like a standard binding mount, as you set the template across the two boards and secure tightly (again, I used other stickers and overlaid the template to allow future re-use).

Mark and punch crosshairs from template for rear Track Block. I ran into a tricky problem due to the slider track that Jeenyus and Forum use, and chose to drill 3 holes and mount one hole directly into the existing slider track, as I would have had no board structure for the 4th hole – note larger silver bolt (I had to enlarge the counter-sink hole in the Track Block so the snowboard binding bolt was flush with the Track Block).

Ensure that Slider Track will slide onto Track Blocks before drilling!!!!

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Use a 9/64” drill bit taped with a ‘drill stop’ so that you don’t drill through or into the base structure (about ¼” deep). Drill slow young Skywalker, drill slow:

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Once drilled, clean holes of dust and debris and apply marine epoxy to all holes:

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Measure centre-to-centre stance from previous mount, and then repeat above drilling and gluing procedure for front Track Blocks:

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OK... nearly done!!!! Now you can start thinking beer:

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Step 11: All you`ve got left to do is the tip and tail clips! This is pretty easy, now that you`ve grown comfortable with drilling holes all over your board. Consider them speed holes.

Use the sticker template to suck the tips and tails together and punch your drill locations (I used one sticker for both tip and tail, to save one for future application) and then drill your 3/16" holes:

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Install the rivet and bushing to allow the clip to smoothly pivot, use the tapered end of the Slider Pin to fully flare the rivet so it won`t pull out – careful, but firm whackage is required to flare the steel rivet:

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The finished tail clip, not as tight as I wanted, but pretty good for first crack:

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Now just mount your bindings to the Slider Tracks AND YOU`RE DONE!!!!

The finished project mounted and ready to rip the pow pow:

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A close-up of the traditional binding mount:

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The finished and sealed base, now I just need to scrape the wax and polish and structure:

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The board SPLIT and in touring mode (many folks like to reverse the skis for touring, but with a DIY split, I think you would tour this way, so you have the best use of the outside edges:

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Bindings with climbing bars up (see what I mean about perhaps a higher post):

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Range of motion – can you say free pivot sweetness – she's gonna' climb my a$$ off:

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Just sitting and waiting for a trim skin and the snow to finally hit the Coast Mountains:

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WHEW.... thanks for that. I hope you enjoyed my journey. Just putting down in text has helped me relive the horrors, the fears, the excitement, the exhilaration, and gain the closure I needed. Sadly to say, I look forward to doing my next one (just certainly not ever for me – I'm a tele-guy... so sorry).

I'm gonna' go suck back some beer.


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Tue Dec 09, 2008 11:21 am 
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Joined: Sun Nov 09, 2008 11:16 pm
Posts: 346
Nice work whitehonky! :rock:
For you heel riser problem i would suggest installing a G3 heel block that has two differnt height bars. Prior did this for me when they sent the board, but I can't imagine why you couldn't DIY (it'd be the easiest thing you've done so far)

You also got work on that inferiority complex about telemarking. I prescribe 2 :guinness: and a :doobie: (thanks for adding that one SanFrantastico ) and you should feel :bananas: in not time

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Jones Solution 164, Fuse baseplates w/BM Bisquits, Salomon Malamutes


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Tue Dec 09, 2008 3:04 pm 
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Joined: Mon Jan 01, 2007 5:00 pm
Posts: 28
whitehonkey,

I probably don't have the requisite qualifications, but whatever...welcome to the 'underbelly' of the backcountry. Yer a telemarker :thumpsup: uh...I mean... :nononno:

Nicely done. :headbang:


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Tue Dec 09, 2008 6:40 pm 
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Joined: Mon Jun 25, 2007 5:34 pm
Posts: 38
Location: EUGENE, OR
The board looks great. Couldn't you just move the heal riser forward to get the height you want? Seems like it could be an easy fix


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Tue Dec 09, 2008 7:29 pm 
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Joined: Tue Jul 12, 2005 5:12 pm
Posts: 1598
Location: Now Oaktowntastic
Really nice write up!

Solo - actually, the spacing between the touring bracket and the heel block is set by the size of the Voile crampon. For fixed mode, the tail end of the crampon sits in the gap under the heal block and the nose end of the crampon is pinned to the touring bracket. Likewise the spark crampon uses the heel block for fixed crampon mode, although there's usually no need for it.

You can buy a tall climbing wire from voile for $14.

What the people over at ttips don't understand is that we're all telemarkers over here too. Were just really bad at it and we only do it as a last resort. Also we don't braid our beards or dry our own fruit. :bananas:

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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Tue Dec 09, 2008 8:42 pm 
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Joined: Wed Oct 06, 2004 10:57 pm
Posts: 4956
Location: California
Looks great! And thanks for documenting the process! 8)


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Wed Dec 10, 2008 11:34 am 
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Joined: Wed Nov 19, 2008 5:20 pm
Posts: 12
Thanks for the comments. I like the 'underbelly of the backcountry' comment.
Nice to see cross-posters from ttips here.
My buddy just picked up a Mojo the other day, so maybe I'll be gettin' some TR's up on here over the winter if the Whistler bc ever gets any. :scratch:
Pouring rain in Vancouver, and only 3cm up at Whistler. WTF?


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Tue Dec 16, 2008 10:33 pm 
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Joined: Fri Nov 19, 2004 8:41 pm
Posts: 1620
Location: Santa Cruz, CA
I assume from the pile of bike parts in the first picture that this is the same whitehonky that posts those lame mtn bike pictures on ttips. Sorry about the crappy terrain you have over there. :) However, since you joined at 4:20, you should fit right in over here.

Nice writeup (for a telemarker!). A few random comments:

- I'd still suggest skinning with the board halves swapped.

- Try the regular climbing wires first. If they feel to short, just swap them with the long climbing wires that Voile sells.

- I'm sure you could have mounted the heel block with wood screws. In my first DIY split, I mounted everything with wood screws, even the touring bracket. I only rode it a couple times (sold it because it was too short), so I dunno how it held up. People recommend t-nutting everything just to make sure stuff doesn't pull out at the worst possible time, which is a good idea for something to be used in the backcountry, but yeah I'd think the heel block would be OK. On the other hand, most people t-nut the pucks nowadays too. People have had the wood screws rip out.

- Having access to a table saw or some kind of guide when making the cut helps keep things straight.

- When finding the balance point, I suggest temporarily placing all the remaining hardware in rough locations... as it can affect the balance point! Probably not enough to really matter though.

- That same free-pivot sweetness that makes the climb nice makes things really "interesting" for short downhill skiing sections.

- If your wife takes to splitting, if you really want to impress her buy her some Spark bindings!


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Wed Dec 17, 2008 1:36 pm 
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Joined: Fri Nov 12, 2004 1:43 pm
Posts: 439
Location: Western Washington
SanFrantastico wrote:
Also we don't braid our beards or dry our own fruit. :bananas:


I'm clean shaven, but my wife dries the fruit...does that count?? :lol:

Nice write-up. I have a jig for my table saw for the cutting part. Got to fix the damage to it, though. Very handy for making the cut(s). Mounting the heel risers with wood screws will be ok, never had any problem over the years with them. Now pucks, on the other hand...and I always damage the core when I rip 'em. :cry:

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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Thu Dec 18, 2008 11:15 am 
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Joined: Wed Nov 19, 2008 5:20 pm
Posts: 12
jimw wrote:
I assume from the pile of bike parts in the first picture that this is the same whitehonky that posts those lame mtn bike pictures on ttips. Sorry about the crappy terrain you have over there. :) However, since you joined at 4:20, you should fit right in over here.

Nice writeup (for a telemarker!).

- If your wife takes to splitting, if you really want to impress her buy her some Spark bindings!


Yup.... same whitehonky. need some shifters???? the pile grows and grows and grows. sorry you hate my mtb shots... I'll keep them clear of this forum. :cry:

If she takes to splitting, we'll go for the Sparks - next year.


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Thu Dec 18, 2008 12:42 pm 
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Joined: Thu Jan 05, 2006 9:44 am
Posts: 136
Location: cascades
nice job buddy. i wish i could get my hubby to do that for me. :)


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Thu Dec 18, 2008 5:23 pm 
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Posts: 1620
Location: Santa Cruz, CA
whitehonky wrote:
jimw wrote:
I assume from the pile of bike parts in the first picture that this is the same whitehonky that posts those lame mtn bike pictures on ttips. Sorry about the crappy terrain you have over there. :) However, since you joined at 4:20, you should fit right in over here.


Yup.... same whitehonky. need some shifters???? the pile grows and grows and grows. sorry you hate my mtb shots... I'll keep them clear of this forum. :cry:

You know that was a joke right? Sometimes the power of the smilie doesn't translate. Anyway I love your mtb shots and am just jealous that you have access to all that stuff right out your door. Feel free to post mtb pics on this thread!

Umm... got any spare SRAM Attack trigger shifters (2:1)?


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 Post subject: Re: Splitmaking - give a telemarker a board and make lemonade
PostPosted: Thu Dec 18, 2008 11:24 pm 
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Joined: Wed Nov 19, 2008 5:20 pm
Posts: 12
yup... knew it was a joke... saw the smilie.

funny you mention the Attack shifters, because I just installed a set on a friends bike last month that I had kickin' around, but he may come back over Xmas and go with a full SRAM kit for 1:1, and then I could throw them your way for the price of shipping. I'll let you know if it goes down.


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