so last season I actually made my my little guy Hank a pair of skis call them Hanks planks they turned out turned out great he loved them there are twin tips I couldn't find any twin tips this small is kind of fun to have skis that I made on his feet for this project basically what I used was Altered birch plywood I was actually given a lot of materials by a friend of mine Dirk who makes skis in his back shed his wife Kelsey actually did the graphics for these skis so thank you to both of you guys I couldn't have done this project without you guys got the edge material the base material from them I bought the fiberglass at a local hardware store you can buy it at a plastic supply store at the same places you're gonna get your your west system resin and hardener of course I used my my PPE used a table saw with a bill but you could easily use a circular saw a router is invaluable to definitely need it you know to make things like you know there's the mold is I use my my drill my shot back if you have a vacuum pump that would be great I did use a car in this video what you'll see at the end see if I can find them here well there they are I failed spring clamps to be really expensive so I actually made my own clamps it took piece of ABS pipe you could probably do with PVC as well cut them in small sections just sliced it right through there and it'll just clamp right on CA glue super glue works really well don't use hog glue I did it with really simple tools in my garage I don't have a CNC machine I don't have any specialized equipment that's sort of the idea behind this I want people to be able to do this easily I'm gonna show you around basically step-by-step how I did this the process is exactly the same whether you're making a kid's pair of skis you're making a big boy pair of skis or big girl pair of skis to begin I traced a ski I had for Hank already onto a piece of MDF that I had used to make the blank making twin tip so it needs to create a tail shape I used a piece of flexible plastic to do this using a jigsaw I carefully and slowly cut the blank into the correct shape I drilled a hole in the middle of the blank using a hole saw and using a quarter-inch router bit router to channel into the blank this channel will be helpful later when using this plane to cut out the cores in the bases anchor would even come out to the garage from time to time to help supervise using the blank as a template I traced the shape under the ski onto a place of Baltic birch plywood then rough cut the shape with a jigsaw before placing a plywood core onto the blank with the shopvac connected to the hole which is used to secure the blank to the core for rotary using a flush cut trim bit this process ensures each core to be exact copies of each other over at the router table I used a 45 degree chamfer bit to taper the core edges then using a hand planer I tapered the cores to the correct stiffness you can use a belt sander or if you have a bench planer you can build a jig to do this more accurately using the blanks again with a shop-vac turned on to secure the base material in place I used a trim bit in my router to cut out the base material be sure to do this with a rough side facing up then I cut the metal edges to the correct length you can use a grinder or crimp the material and then snapping it the way I did here using clamps to hold the edges I used CA glue to glue the edges into place to make the form I used some MDF I had laying around I cut strips in the MDF and then trace the profile of the ski onto the strips being sure to mark the tip and tail not to mix them up then very carefully cut this profile out using a jigsaw I then use this cutout as my template for the rest of the mold I secure the cutout on two pieces of MDF that I wanted to cut next spacing the top and the bottom of the pieces the same distance of the bearing on my router bits then using a flush trim bit I made an exact copy of the original pieces repeat this process as necessary to build them all to the correct thickness I then bolted mould sections together to ensure the mould remained monolithic during the pressing process movement of the mould sections would be create a non uniform ski profile for peel ply I used a sheet of poly and just poked holes in it using this wallpaper removal tool for the layup process I used a resin to harden a ratio of three to one and mixed it really well I started by wetting down the bases then lay the first layer of the cloth and why did that as well I've tried to put the graphics under the claw so I just peeled it up and read squeegee the cloth I then wetted the course with resin before putting them in place to ensure uniform coverage of the resin then cover the cores with a second sheet of cloth which was of course wetted and squeegee I printed the graphics under rice paper which will absorb the resin and become part of the skis I then place the skis into the vacuum bag which I made with poly the peel ply was placed over the skis and then 2 towels to absorb the resin that seeps through the holes in the peel ply manually seal the edges of the vacuum bag pressing the butyl caulk to create an airtight seal I hooked up my vacuum to the bag and turned it on to draw it down the vacuum bag with the bag suelen to vacuum I placed everything in the mold I place a piece of camping foam over the bag and close the valve sealing the vacuum in place then disconnected the vacuum hose to make it easier to pick everything up I placed it on top of the mold and then using some ratchet straps I place some pressure on the mold to keep it in place I then put the mold on the floor of my garage and just drove my car onto it note that the vacuum is hooked up again I drew the vacuum every hour or so while the skiis cured after curing at room temperature for 12 hours or remove the skis from the vacuum bag and allowed further cure for 12 hours before cutting out with a jigsaw Henry got a lot of use out of his skis this year he really liked them we were looking forward to the ski season coming up so that he can use them again in previous videos I was talking about Leo's project the Sampson boat company rebuild of Tallyho in August I said any plans that I sold for my bed desk I would donate half the money to Leo I sold about five plans I was really hoping to sell more so that's about 50 bucks going to Leo but I'm just gonna throw in everything so it's gonna be a hundred bucks alone allele so ever thanks to everybody who took the effort to actually buy the plans from me to support Leo's project it's kind of a really cool thing I think he's got to be the hardest-working guy on the Internet I always feel bad sitting on the couch watching his videos if you like this video let me know give me a thumbs up maybe if you want you can subscribe otherwise you know share it around show your friends thanks very much watch for my next video you

How to Make Skis At Home – Hank's Planks
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15 thoughts on “How to Make Skis At Home – Hank's Planks

  • June 1, 2019 at 6:35 am
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    Great video! I'm a senior and high school and for my senior project this spring I am going to be making a pair of skis. I would love to possibly get in touch and hear any advice or tips you could share on the project

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  • June 1, 2019 at 6:35 am
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    hi great video. question about your lay up. what did you use to keep the skis from sticking to the vacuum film? looks like a cloth or towel . Is this a peel and ply material ? Can you give the lay up in order of operation from base to top ? it would be greatly appreciated. you did great job on this.

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  • June 1, 2019 at 6:35 am
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    so is the whole ski made of Baltic birch plywood? or is the ski made from different types of layers?

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  • June 1, 2019 at 6:35 am
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    Do you know where to get the metal edges?

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  • June 1, 2019 at 6:35 am
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    What did you use as a base material?

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  • June 1, 2019 at 6:35 am
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    What's your problem with kiwis.?
    Noticed you comment on another video.
    Is it typical of people in your country to judge populations of countrys as a whole, maybe that's why you spread your messages through bombing others.
    My retarded kiwi kids build their own skis from the age of 4.
    Be careful about judging people, it's very ignorant.

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  • June 1, 2019 at 6:35 am
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    Really enjoyed watching this! Greetings from /r/DIY!

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  • June 1, 2019 at 6:35 am
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    What a fantastic project! Hank looks right at home on his planks.

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  • June 1, 2019 at 6:35 am
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    Honda Element as a clamp?! Instant subscribe 😉

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  • June 1, 2019 at 6:35 am
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    you have a dopelganger in utah

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  • June 1, 2019 at 6:35 am
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    Why do you have to edit the shit out of the intro?

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  • June 1, 2019 at 6:35 am
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    Wow that's awesome. How long did this project take you overall. I'd love to try this but doubt I can find the time.

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  • June 1, 2019 at 6:35 am
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    This project was a lot of fun, and a decent amount of work! But it's great to see my little guy on a pair of skis that I made

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  • June 1, 2019 at 6:35 am
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    This is awesome! Im totally going to make my next pair of skies.

    Reply

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