Ski Building

  I was finally able to start working on my skis and complete everything that would finally shape them. This was by far my favorite part. I was able to see the skis that I have been dreaming of making for the past year finally take form. I got to cut them out into the perfect form. The instant that all of the sanding was done I was finally able to take a step back and respect the skis that I had just made. They were perfect on every level. I did not make a single mistake on my skis which I was very happy about. The instant that I was able to paint the wood polish onto my sidewalls I was extremely happy.

  I started out my senior project by. designing my top sheets. The top sheets are designs that you see on the top of a ski. I wanted them to be memorable so I created roughly ten designs that me and my brother would be able to pick from. I found photos that I had taken on vacations of mountains and fields and decided to give them a shot. They did not come out how I wanted, so I decided to take a photos off the internet that reminded me of things that I have experienced. I sent the designs to a company that prints out top sheets and they are currently in the process of printing them.  Once I had everything set with my top sheets I was finally ready to start designing and building the ski. I started out by learning how to cut bases using the cnc machine. The cnc machine has a replaceable bit and while cutting the bases I used a razor bit. Once the bases are fully cut they need to have edges glued onto them. I have a roll of ski edge that I cut sections out of to perfectly fit the length

 Today I started cutting and shaping the skis that I am making for myself. I took them out of the ski press last night and let them sit overnight. When they came out of the press they were in one single piece and I have to cut each ski out separately. I used a jig saw to cut each ski out.  I had to be extremely safe not to cut into my skis while shaping them with the saw. The saw will cut right through the metal edge. Once I have the edge, tips, and tail completely cut I am finally able to start sanding the sidewall away. I was able to get the majority of my ski sanded and ready to have an angle cut in the sidewall. I also prepared my brothers skis to be put in the press. I put them in the ski press once everything was completed and left them there for 8 hors. Hours-10

I started out the week by designing my top sheets. The topsheets are designs that you see on the top of a ski. I wanted them to be memorable so I created roughly ten designs that me and my brother would be able to pick from. I found photos that I had taken on vacations of mountains and fields and decided to give them a shot. They did not come out how I wanted, so I decided to take a photos off the internet that reminded me of things that I have experienced. I sent the designs to a company that prints out topsheets and they are currently in the process of printing them.  Once I had everything set with my topsheets I was finally ready to start designing and building the ski. I started out by learning how to cut bases using the cnc machine. The cnc machine has a replaceable bit and while cutting the bases I used a razor bit. Once the bases are fully cut they need to have edges glued onto them. I have a roll of ski edge that I cut sections out of to perfectly fit the length of my skis. Onc

  I continued to carve out ski cores this week. I had roughly 7 finished going into the week and I will eventually need to create 12. The process of cutting the cores using the cnc machine is extremely difficult and it was never exactly planned. I have cut four different cores and every single time I have had something go wrong. My most recent complication was that the drill bit was overused and dull. It was not able to cut properly so it jumped around whenever forced to cut something. Using the cnc machine is by far my least favorite part of the project but it is extremely important because it basically creates most of the ski.  I have had issues with getting the top sheets that I made at the very beginning of my project. The order keeps on getting delayed because the company that I bought them through ran out of materials. They arrive this friday but this means that I am going to be forced to work through the weekend. I was able to create my dads ski because we are using wood veneer

  I have had issues with getting the top sheets that I made at the very beginning of my project. The order keeps on getting delayed because the company that I bought them through ran out of materials. They arrive this Friday but this means that I am going to be forced to work through the weekend. I was able to create my dads ski because we are using wood veneer to design the top. This allowed me to learn how to layer and mold a ski before I have to do my own. I learned how to cut the fiberglass, combine the core with the nose and tail piece, and layer everything together with epoxy. Once everything is layered I am able to put it in the press. The skis stay in the press for roughly 12 hours to ensure that the epoxy dries properly. I also started to create the skis that i am making for myself Hours-10 Total Hours-61