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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Tue Feb 07, 2012 9:59 am 
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Joined: Thu Oct 20, 2011 12:09 pm
Posts: 27
So, any news on this project?

I love the use of carbon here, and would like to see how you plan to lock the binding in place in ride mode.


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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Thu Feb 09, 2012 7:07 am 
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Joined: Wed Jan 04, 2012 2:59 am
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Location: Amsterdam
No news, waiting for parts before I can proceed. :?

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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Tue Feb 14, 2012 12:48 pm 
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Joined: Thu Jan 14, 2010 1:28 pm
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Location: Cottonwood, UT
It would be very interesting to see if the pucks can take the frequent loads from riding. I see a potential watchout where the engagement flanges step down to the main body of the pucks. The 90° angle there is an area of stress concentration. The best thing to do would be to transition the flanges down to the surface of the puck by adding some material to form a radius or fillet. The same goes for the underside of the puck where it meets the flanges. I imagine that if it can fail, that will be the spot. However, I'm not familiar with the material properties of carbon. If its strong enough it may not ever be an issue.


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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Tue Feb 14, 2012 1:43 pm 
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Location: Amsterdam
The cutouts were not cut in a sharp angle, but have a small radius because that is an area where it could fail. The pucks are also bolted down off course, and they don't really bend either.

I'm not that worried about the underside of the puck where it meets the flanges. It seems pretty strong, but we won't find out untill we ride it hard for some time.

If I would have made the pucks out of solid steel, would you think that is strong enough?
Good carbon fibre is very strong. A lot of people think it is like aluminium, but it's not. It's actualy stiffer AND stronger than steel. It's just not very good at handling impacts, like hitting it with a hammer or something but I don't see that happening when it's locked into place and my foot is on it..

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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Tue Feb 14, 2012 2:02 pm 
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Joined: Thu Jan 14, 2010 1:28 pm
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Location: Cottonwood, UT
Cool. It looks like you've though this through. Good work and nice innovation. I'm excited to hear about the maiden voyage.


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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Sun Mar 11, 2012 7:09 am 
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Joined: Wed Jan 04, 2012 2:59 am
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Location: Amsterdam
Been a while since the last update. The bad news is that I still didn't get my pins for the LT brackets, so I couldn't get the touring mode done before my trip.
I ordered them from www.splitboards.eu but after months of waiting and sending mails they finally let me know they won't be getting the pins untill next season. This sucks.

I'm now thinking of not bothering to get the pins at all and build a system similar to the new Sparks that have a fixed pin in the brackets.

But I did finish everything else and took my board on trip. We chased the snow for 4 days in Switzerland and I think this was a really good test for the board in ride mode at least. I rode everything from pow to ice, and only used the splitboard.

Nothing broke, the carbon interface is easily strong enough. The board still feels light, and I don't notice any difference at all as a result of splitting it. I expected it to be less stiff and not hold an edge on ice or carve as well as before, but I don't notice it at all. This is a board i've been riding for 2 seasons, so I know what it felt like before splitting.

It did feel a little slower on flats, probably because of the epoxied t-nuts and the cut in the middle. But I was still faster than my buddies on Salomon sickstick's, probably because I wax my board very well before every trip.

The bindings are very stiff and responsive and are positively stuck solid to the baord by the pucks/disks, no flex there at all. They felt more responsive than my Cartels.

I should have some pictures of the trip next week.

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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Wed Mar 21, 2012 9:34 pm 
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Location: Revelstoke
Are you thinking of making these pucks to sell?


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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Thu Mar 22, 2012 12:22 am 
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Location: Amsterdam
I've thought about it, but since i'm in Europe there isn't much point in shipping pucks to splitboarders in the US. It will be too expensive. But I would not mind if a lot of splitboarders could benefit from this, I still think this the cheapest lightweight solution.

My idea was to give the CAD drawings to Rughty, so he can have some sets made. This makes more sense to me because he already has a neat solution for mounting the bindings to the touring bracket. He's also much better at machining stuff in general. We also compared some prices for waterjet cutting and that seems a lot cheaper in the USA as well.

Here's a pic of the split in action:
Image
Image

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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Sun Mar 25, 2012 10:42 pm 
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Finally had a little time to work on the binding again yesterday. I started making the parts that will hold the binding to the touring bracket. This is 250g/m2 uni carbon in two layers pressed without vacuum, so it's not strong enough to bear loads. I just wanted to get all the dimentions and angles right first.

These parts will go into the vacuumbag later where I will bond the binding to it with additional layers of carbon.
But putting the whole pin and brackets into the vacuumbag was not an option, the forces of the vacuum would force it out of alignment so I wanted to get this sorted first.

I made a mould out of plexiglass that has the same shape as the binding baseplate, and waxed it with mould release. You can see I used the brass bushings theat normally go into a Spark binding, the carbon will go around that. Thanks Jeff from Spark for sending me these!
The "pin" I used is a fibreglass rod from a kite, real pins are not available right now in Europe.
Image

The whole thing clamped in place. It has peelply on both sides so additional layes will stick. The yellow is just cloth to soak up extra resin.
Image

Image

Finished!
Image
Image

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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Wed Apr 04, 2012 8:03 am 
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Joined: Fri Feb 17, 2012 6:55 pm
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put extra layers of carbon around the metal insert and all the way to the first screw. also make the holes further away from each other if the binding base allows. Mine broke on the last trip and it's because of the the 2 holes being so close.
Image
My binding base had 4 connected holes and I made an extra one. on the left side there was little space for a 4 mm hole so that's where the touring bracket broke.
Image
I also thought putting the 3 screws in a line would not be good somehow. but now I'm thinking about making the bracket longer like yours and have the third hole done behind the original holes. Your base might be different though!
How will Mr Chomps connect to the board?


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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Wed Apr 04, 2012 11:01 pm 
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Location: Amsterdam
That's a good point, but my binding has even less material in the toe area than yours. So I didn't plan on any screws in the baseplate at all as it's not possible.

The RX has a removable toeramp, if you take that off there is not enough room to even consider two or three bolts.

It will be bonded to the binding, and the carbon will follow the binding in an L shape at the sides of the foot just like the binding. Vacuumpressing will pull the carbon in the cutouts that are in the binding and the screw that mounts the toestrap will secure it in place even more.

But it's good to see the force that is put on the whole thing is enough to break such a part. I will make the carbon thicker and a bit longer underfoot to be sure.

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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Thu Apr 05, 2012 8:07 am 
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Joined: Fri Feb 17, 2012 6:55 pm
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since u can play around with the carbon why not try to rebuild the toe ramp with the metal inserts inside. smth like this:
Image
You can put small pieces of polystyrene where u need to create space between carbon. This will create a strong structure while keeping the whole thing light
I'm not sure how well the carbon sticks to the aluminum but i would rather put at least 2 more screws in there somewhere and make it removable. Keep in mind that if any of these parts fail you might be somewhere far away in really deep powder and not be able to get out. mine broke just half an hour into the trip and what should have been a max 4 hour fun tour turned out to be an 6 and a half hour struggle with the snow. :cry:


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 Post subject: Re: How to build a splitboard WITHOUT a Voile splitkit
PostPosted: Thu Apr 05, 2012 1:10 pm 
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It won't be much different than your drawing, but probably not so much of a toeramp.

Vacuumbagging small parts is tricky, and the more loose parts you have the more can go wrong. So no polystyrene inserts and trickery, I'll stick with making a simple design that works first.

I don't need it to be removable, the more solid it is fixed to the binding the better. I might put one screw in the middle, that's the only logical place where it can go on my bindings.

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