Alpine Skis

The aim for this project is to design and assemble downhill, all mountain skis. The further goal of this project is design the framework, workflow, tools, and procedures of a repeatable process for potential future students.

Maple Wood

Ash Wood

Sandwich Tech Ski Material Kit

Sidewalls

10x 2x4

Vacuum Bag

Resin Release Film

Vacuum Hose

Vacuum Bag Fitting

Vacuum Pump

Vacuum Gum Tape

2x 1/2" NPT to hose barb

1/2" NPT One-Way Valve

1/4" Female Flare to 1/4" Pipe Thread

Resin Press Blanket

1/2" Maple Plywood for templates and router sled assembly

Clamps

Double Sided Duct Tape

Duct Tape

Wood Glue

Band Saw

Table Saw

Router Table

Router w/ Handle Attachment

Sand Paper

Glue Scraper

Planer

Exacto Knife

Masking Tape

Chisel

Hammer

Flush Cut Router Bit

Straight Router Bit

Jig Saw

We used Solidworks to model the ski core, ski base, our sled jig to profile the skis, and our press shape. We sent these files to a connection a Sierra Space who was able to cut the files into plastic templates for us to use.

1. Cut boards into desired width
2. We used:
3. Ash: 20mm x2 and 25mm x4
4. Maple: 30mm x4
5. Glue wood together (small ash in middle sandwiched by maple sandwiched by big ash)
6. Use miter saw to cut ends to desired length

1. Transfer plastic template to wood (½ in maple)
2. Cut out wood template using band saw and sander
3. Using wood template use table router with a flush cut bit to cut to template shaping the core, don't forget to get close to the template using a bandsaw first, within about 1/2" of the final shape

1. Align and glue sidewalls to side of ski
2. Clamp sidewalls to ski core to hold them tight
3. Let glue dry and use miter saw to remove excess wood from ends of sidewall
4. Use hand planer to get sidewalls close to core

1. Use side profile template to cut out rail onto ½ in maple. X2
2. Cut out 5 middle supports and 2 end supports to run as a base for core to sit on when using the jig.
3. Glue and clamp supports evenly throughout the distance of the rails
4. Cut out wood for router sled
5. Glue up and build router sled

1. Lubricate router sled
2. Setup router with correct bit and handle accessory.
3. Measure and test run height/depth of router bit on scrap wood
4. Clamp cores to jig and run router across in sections (moving clamps across ski for sections) using back and forth motions.

1. Transfer plastic template to ½" maple board
2. Cut out template using band saw and sander (part of step one)
3. Cut P-tex sheet in half with band saw
4. Use double sided duct tape to cover template
5. Tape p-tex onto template
6. Slowly use table router with flush cut bit t cut p-tex to template.
7. Remove p-tex and tape from template and repeat once more.

1. Use exacto knife to cut the round at the end of the edge pocket to 90 degrees
2. Using dremel cut edge to correct length
3. Using resin or CA glue glue and clamp edge to rough side of base in sections. (use lots of clamps to make sure edge bend matches the radius of the ski)
4. Repeat until all 4 edges are connected.

1. Make graphic using photoshop
2. Using sublimation press transfer top sheet design into ski top sheet.

(We reached out to a ski company to sublimate, not required for completion)

1. Transfer template shape to 2x4
2. Cut out 2x4 using band saw (close cut)
3. Sand 2x4 to lines using drum sander
4. Trace and repeat 9 more times for all of the 2x4s
5. Glue and clamp 2x4s together (make sure correct sides are lined up) let dry
6. Using glue scraper scrape off excess glue from press
7. Using hand belt sander, oscillating sander, and sandpaper to sand down press till top side is smooth and lined up, do this while keeping constant shape.

1. Lay press on top of vacuum bag sheet and fold bag over, then roll opposite edges of bag together to correct size and using tape gum seal edge and finish with duct tape. (short side)
2. With press lined up correctly inside the bag line gum tape inside the end of one open side of the bag. Then roll the end and tape and seal using duct tape.
3. Insert press and materials such as base, core, and top sheet and roll and seal the open end with tape. After this turn on the press and check that it seals and pulls a tight seal and patch any holes in the bag using duct tape.

1. Lay down protective sheet or material below press
2. Prepare all layers and materials needed (resin release film, core, top sheet, base, fiberglass, resin, vacuum bag, vacuum pump)
3. On press lay down each layer in order: release film, base, fiberglass, core/p-tex in ends of ski, fiberglass, top sheet). Between each of these layers thoroughly apply resin coating all surface area (make sure fiberglass absorbs resin). And make sure when laying layers place them in desired location.
4. Hold layers in correct placement and slide press into vacuum bag.
5. When press is aligned inside bad roll open edge and place gum tape inside roll to seal. On top of that using duct tape to seal edge and outer rim of the roll along with the corners.

1. Check the order and tightness of the adapters and hose connecting the pump to the bag.
2. Plug in and turn on vacuum pump and confirm seal is being made.
3. For 30 minutes run vacuum pump after this alternate on and off (timing of this will very with different pumps, how sealed the bag is, etc.) with the pump to make sure that it doesn't overheat (when doing this don't let the bag get loose). If you are not using a one way valve in the connections within the hose then continuously run the pump.
4. Run pump for 6-12 hours (we ran for 6). Warmer temperatures helpful.
5. After time is up allow it to sit and cure for 6 days on press.
6. Step 4 benefits from more time in the press.

1. After waiting for Epoxy to cure remove skis from the press and peel resin release sheet off the bottom of the skis.
2. Using jig saw, separate skis the long way
3. Using glue scraper carefully scrape off any excess resin or bumps off of bottom part of the ski.

1. Using band saw cut around the tip to get it close.
2. Then using belt sander sand around the tip until the middle p-tex is flush to the outline of the base

1. Using belt sander sand the excess sidewall down and close to the edge. (if possible try and give ski sidewall a slight angle
2. Used the glue scraper to scrape excess Epoxy off the sidewalls of both ski’s.
3. Taped the edges off for resin, so that it didn’t get on the top sheet or the base.
4. Applied resin to the sidewalls using popsicle sticks, then wiped of excess with paper towels.
5. After waiting 48 hours we lightly sanded down the edges with high grit sandpaper to make sure it was flush to edges.

Finished Skis!

(Take to shop to mount bindings [mark the recommended mounting point on your skis for them] and tune [you must ensure there is no excess resin to protect the shops belts])