Historical Context & Materials

• Stand-up paddling popular sport, paddle boards exist 3,000+ years
• Contemporary boards use modern materials for light, reliable construction
• Board made with vinyl ester resin and laminated fiberglass
• Features: onboard lighting system, anchor, neoprene rubber non-slip pad

Gel Coating Process

• Technician applies release agent on paddle board mold for smooth, clean surface
• Fin channel positioned using thin fiberglass template as guide
• Airless pumping system sprays mold with vinyl ester gel coating mixed with hardener
• Mil gage used to ensure even hull thickness

Hull Construction - First Structural Layer

• Three-quarter ounce bi-directional fiberglass mat used for first structural layer
• Fiberglass panel pulled out, covers gel coated surface
• Fabric scissors cut mat, fiberglass skin made tight as possible
• Mat torn to conform to rounded gel coat shape
• Vinyl ester resin applied with paint roller
  • Resin saturates fiberglass, merges with gel coating
• Extra material placed over fin channel for structural bond strengthening
• Bubble roller removes air bubbles
• Second fiberglass coat applied for reinforced structural integrity

Assembly Room Operations

• Template fitted on board deck, hand grab mount contours traced with pencil
• Air saw cuts slot in fiberglass laminate for hand grab
• Hand grab mount bound to hull with vinyl ester resin coat
• Laminate hardens within ~20 minutes

Internal Systems Installation

• Plastic tubing for internal anchoring system installed
• Bonding adhesive applied to secure tubing
• Tube attached with tie wraps to prevent tangling inside hull
• Jam cleat installed for rope manual anchor control from deck

Foam Stringer Installation

• Cured vinyl ester resin firmly bonded to structural laminate
• Expanding adhesive applied
• Expanded polypropylene foam stringers positioned inside hull
  • Foam stringers = board backbone
  • Support paddler weight on deck while maintaining light weight
• Nylon wedge and rubber mallet remove mold from hull

Final Assembly

• Two assemblers lift and flip lightweight hull onto cart
• Excess laminate trimmed with air cutter fitted with diamond cutting blade
• Foam stringers leveled with file blade for tight hull-deck fit
• Expanding foam adhesive applied on stringers before deck placement
• Deck placed with co-worker assistance, adhesive quickly binds parts
• Vinyl rubber rail provides side protection, masks deck-hull joint

Power Systems & Features

• Dry storage hatch contains onboard battery
• 8 amp hour battery activates power pole (micro anchor for shallow waters)
• Deeper waters: manual internal anchor system activation with 16-foot nylon cord