HD Foam-Block Installation

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• HD (High-Density) Foam-Block Installation Procedures (1.7 MB)

Installation Guide

These high density foam installation procedures are designed for those fin configurations that are likely to experience heavier than normal water resistance such as tow-boards, twin fins, kitesurf boards and surfboards made for the more heavier powerful surfers.

HD-Blocks can be easily installed as standard in Vs and blanks having up to 3-4mm of tail concave. Contact your nearest 4WFS representative for more info on those blanks that have more extreme concaves.


HD KIT COMPRISES THE FOLLOWING:

1. 3 x placement sponges/card (the card can be re-used by spraying glue adhesive after each use)


2. 3 x HD (high density) circular foam cut-outs (cream in colour).
   HD-Foam blocks are available in 15mm and 20mm depths(note: different HD jig applies depending on depth).


3. 1 x HD block jig (thin = 12mm) provides for a 20mm deep HD foam block [gives extra strong hold, especially used for Kite and Tow-In boards].
4. 1 x HD block jig (thicker = 17mm) provides for an 15mm deep HD foam block [gives extra support for Twin-fin configurations and extreme surfers].

HD INSTALLATION PROCEDURE:

Please note that all HD-Blocks are 6.5mm wider than the rim of the round 4WFS box!

1. 1. Ensure that shapers fin marking "dots" are 4 1/2 inches or more apart and draw a line between the front & rear fin placement dots. (fig.1)
   
   
   
   
2. 2. Blow the blank of all excess foam dust.
   
   
3. 3. Remove paper backing on the jig placement sponges/card and position as per the usual 4WFS installation procedures onto the shaped blank and the markings provided. (fig.2.1/fig2.2)
   Note that in most cases it is only necessary to remove the 4 corners of the backing paper to obtain a secure placement on the board; you can re-use the sponges after the board is laminated in order to router out the box recess.
   
   
   
   
   
4. 4. Using the NEW HD Block Jig (either thick or thin), position over the sponges/cards ensuring that the jig fits snugly all around the sponge or card and flush with the foam's surface. (fig.3)
   
   
5. 5. Using the router at the standard 4WFS depth setting, place over and in the NEW HD Block jig (thick or thin) and begin cutting the foam away from the centre in a circular motion spiralling away towards the sides of the jig (this reduces sideways pressure on the sponges & jig).
   Note that is is OK to router into the sponge (as the HD-block is bigger than the standard box). You can still re-use the sponge after lamination over HD insert. The 4 stabilizing tab cut aways are no longer visible, as you only need to ensure that the weighted alignment jigs are correctly recessed into the top and bottom area of the sponge.
   
   
6. 6. Blow all excess foam dust away.
   
   
7. 7. Take the 3 Pre-Cut HD Circular Foam Cut-Outs and paste them with laminating resin on the underside and sides of the foam and inside the walls of the holes cut into the shaped board and insert them into the recesses that have just been cut. This can be done separately or with the same laminating resin mixture you are using to laminate the bottom deck.(fig.4)
   Tip: Place a 20mm long self tapping Tek-Roofscrew through the middle of the HD-block to ensure it remains flush with the board until the resin has gelled.
   
   
8. 8. Apply 4 oz cloth patches under or on the laminate depending on personal reference. Cut the cloth patches 1- 2 inches wider than the foam blocks and continue to laminate as usual.
   
   
   
9. 9. Once the board has been laminated and has had its sand-coats (gel-coats) applied, then install 4WFS as per the regular 4WFS INSTALLATION PROCEDURES.
   Note that as per note 5 you can still re-use the original sponges for routering the recesses for the boxes.