I know most forum users ran off to the efoil.builders website, but for the truly faithful ES members, here's my repost from there. ES is where my gratitude belongs.
I wanted to do a write up for myself and posterity on my own foil adventure. Most of it will be me rambling on about other electric projects, but I will get to the foil part soon enough. If you don't care just scroll down for the pictures. I know I didn't get here first and their were many people with greater skills than I have that helped me and everyone else get to this point,
It'll all started back in 2010. I saw this video on Youtube:
New electric foilboard
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- Posts: 607
- Joined: Oct 18 2012 1:31am
Re: New electric foilboard
I try again with a number of different props and an old 6s boat ESC. The props fly off or break and nothing seems to work. Meanwhile, the weather gets cold and I don't have another setup to try before I am done for the season. I buy as Christmas presents to myself the missing gearbox for the SSS motor and the Seaking ESC.
Over the winter I read up on all the latest as the forum moves over to efoil.builders from Endless Sphere. Still seemed too complicated to run all that stuff with talk of needle bearings, seals, extra shafts and couplers. I know from experience how much more powerful the big motors are. Everything works in my head and on paper. I decided to try out both options from last summer, the c80100 and the Boma motor. I printed a prop for the c80100 motor that enclosed the whole motor with the prop designed on the outside of the can. As the can spun the prop would turn and there wouldn't be a need for anything extra. No waterproofing or anything, just had the cover screwed into the motor. For the Boma 1500w motor, I just fastened a Solas prop on the back with a set screw. This time I try both setups in my backyard pond. I'm not driving to the lake to find out the prop is unscrewing, the set screw is coming loose or the prop blows up and flys off.
After finally getting back to the lake, which is an hour drive or so to get there and fifteen minutes of setup - I'd usually end up with myself getting wet and disappointed. I decide the c80100 looks to be the most probable for getting me going. Also the risk of hitting the open prop is less, which has always been one of my biggest concerns. I get in the water with everything plugged up. The 48v ebike controller, wired remote, pelican case on the front of the board - a Slingshot Simulator 5'2" board which I'd borrowed to give me more float. The case goes under water when I lay prone on the board. As I know that isn't good, I put weight on the back, cautious of the prop, hit the throttle and the board goes. It goes, but not quick enough yet for me to get up on foil. I keep leaning forward on the board thinking that will help. No go. Later I realize what I'd done wrong there... I keep trying for the next half hour or so. Never enough to get up even though in my head things should work, especially at this speed. I keep checking the esc temp and batteries. I'm using the Multistar at 20ah on 12s. Then it happens, the motor is spinning and I'm slowing down. I swim back in with shame. As I lift the board out of the water, the problem is there, no more prop fins. All of them were gone. A guy watching comes over and talks to me about my front wing. He just got a foil and got the huge sup front wing - the infinity from Slingshot - could that be the problem? I figure that's my next purchase. A fool and his cash are soon parted! Too dark to try again, I drive home thinking how I should be leaning back to get on the board to get on foil not forward. Complete opposite of what I did. Would it have worked if I had done that? Should I give up on the motor and move on or was it enough to get up? Was the 3d print off and that is why it broke? My 3d fusion skills are still lacking to just add thickness to the prop, normally a quick job, but for me a few hours of frustration.
    
Determined to just get going as the summer is half over, I bag the idea to reprint the cover and just go with the Solas prop. That thing at least won't blow up on me.
Meanwhile a friend of mine, knowing my trials with building an efoil - has been talking to some people about getting a board. He runs into the same problems as most of us here - there isn't anything available for a decent price. We talk about the fact the whole setup shouldn't be more than a few thousand. I mention, I've easily already spent that over the last five years trying to save that money and have nothing to show for it! I should have just gotten the jetsurf and enjoyed myself all these years. I know that most of the fun has been in the garage, but I won't admit that. I think that is why the ebikers are perpetually building new bikes. It is a way to get your mind off all the other problems in your life. I did the same, the minute I got things working right on one of my projects, I'd move on to the next one before I really spent anytime on the finished product. Talking again with him, I decide that even if I do get this efoil working, I'm going to have to find someone to build a board, build a better enclosure, get a waterproof remote, and finalize a carbon fiber foil mast that will have motor mounts. I do have to face it. I don't have the skills for this project. I can barely 3d print, barely model more than a box. I can barely put together a foil. I don't know how to lay carbon fiber.
I don't know how to chop a surfboard in half and fiberglass the ends. I don't have a lathe and can't mill parts out of aluminum. I don't really know the difference between a ball bearing and a needle bearing. I don't even know what foil shape is best. Heck I can barely ride my foil behind the boat.
I definitely can't pump on the second wave. Who am I kidding on this? He says he knows some people that know some people... The same guy needs the Slingshot board back to do some kite foiling and I'm out of luck. My foil board is stuck in my boat a few hours away, and I'm not getting down there for another month or so. The lake where my family goes is almost empty and has some algae bloom making it unsafe to swim. No more wakeboarding, wakesurfing, or wakefoiling this summer. My kite bladders are even all blown out. Not that we have any wind this time of year either. Ouch! (Still have some fun ebikes though!)
A month or so later, and a few thousand emails, my buddy's contacts send us the board. Just in time for the weather to change for the worse. The season pass is already bought, a new snowboard ready to be waxed. It's the real deal though this efoil, a carbon fiber foil similar to the Slingshot Infinity I'd ordered after seeing it the first time, which still is on backorder. A giant 40Ah battery. A board with a waterproof deck lid, enough space for the controller and battery. The motor, close in size to the Boma but waterproofed with a protective duct and a four blade prop. It had a battery gauge I could see built into the board. None of it 3d printed, none of it that looks like it was made in my garage. My first attempt is heavenly, almost surreal. I've ridden the jetsurf and it was kind of a nightmare. A pain to water start and harsh on my legs and feet. This was different. No chop, felt like riding powder. I was riding on electric power with nothing but a hint of noise from the motor and the rustling of the wake I was making. I rode solid for an hour. My legs sore and stiff from trying to keep up on foil. I'd fallen a bunch and it had taken some getting used to, but it was great. As I am taking the board apart on the beach the sailing crew that was out there kept coming in to take out their boats. Thinking I was hot stuff on the beach, e-foiling, first in the state and all that hard work and effort. How cool must that have looked? A couple of them mention they never saw me get up on foil, doesn't it work they ask. There goes my ego! I want to yell, you try this thing. Its not easy, and plus I was foiling, just would rather crash from a foot out of the water than 3.
But, after all the years, it was sweet. I've been out about ten times in the past few weeks, even with temps getting cold. I remember Hiorth in a Santa suit and tell myself to toughen up. We have had some issues with the board. A remote that wasn't exactly waterproof - which who knew. A foil, like Lift that had too much flex and cracked. All in all, everything seems to work. It should, it is electric. No mixing gas, no clogged carb, no bad plugs. As long as the controller doesn't catch fire, or the battery has issues,then we'll be in good shape. The thing should last for years. I'm done with projects for a while. I do feel like I've cheated, especially seeing all the effort and hard work that has gone into everyone's builds. Finally it's time to ride!
Now for some pics.
              ![20180918_162643|690x388]

https://www.youtube.com/watch?v=s4QURUBh3lA
I will update links when I can.
Over the winter I read up on all the latest as the forum moves over to efoil.builders from Endless Sphere. Still seemed too complicated to run all that stuff with talk of needle bearings, seals, extra shafts and couplers. I know from experience how much more powerful the big motors are. Everything works in my head and on paper. I decided to try out both options from last summer, the c80100 and the Boma motor. I printed a prop for the c80100 motor that enclosed the whole motor with the prop designed on the outside of the can. As the can spun the prop would turn and there wouldn't be a need for anything extra. No waterproofing or anything, just had the cover screwed into the motor. For the Boma 1500w motor, I just fastened a Solas prop on the back with a set screw. This time I try both setups in my backyard pond. I'm not driving to the lake to find out the prop is unscrewing, the set screw is coming loose or the prop blows up and flys off.
After finally getting back to the lake, which is an hour drive or so to get there and fifteen minutes of setup - I'd usually end up with myself getting wet and disappointed. I decide the c80100 looks to be the most probable for getting me going. Also the risk of hitting the open prop is less, which has always been one of my biggest concerns. I get in the water with everything plugged up. The 48v ebike controller, wired remote, pelican case on the front of the board - a Slingshot Simulator 5'2" board which I'd borrowed to give me more float. The case goes under water when I lay prone on the board. As I know that isn't good, I put weight on the back, cautious of the prop, hit the throttle and the board goes. It goes, but not quick enough yet for me to get up on foil. I keep leaning forward on the board thinking that will help. No go. Later I realize what I'd done wrong there... I keep trying for the next half hour or so. Never enough to get up even though in my head things should work, especially at this speed. I keep checking the esc temp and batteries. I'm using the Multistar at 20ah on 12s. Then it happens, the motor is spinning and I'm slowing down. I swim back in with shame. As I lift the board out of the water, the problem is there, no more prop fins. All of them were gone. A guy watching comes over and talks to me about my front wing. He just got a foil and got the huge sup front wing - the infinity from Slingshot - could that be the problem? I figure that's my next purchase. A fool and his cash are soon parted! Too dark to try again, I drive home thinking how I should be leaning back to get on the board to get on foil not forward. Complete opposite of what I did. Would it have worked if I had done that? Should I give up on the motor and move on or was it enough to get up? Was the 3d print off and that is why it broke? My 3d fusion skills are still lacking to just add thickness to the prop, normally a quick job, but for me a few hours of frustration.
    
Determined to just get going as the summer is half over, I bag the idea to reprint the cover and just go with the Solas prop. That thing at least won't blow up on me.
Meanwhile a friend of mine, knowing my trials with building an efoil - has been talking to some people about getting a board. He runs into the same problems as most of us here - there isn't anything available for a decent price. We talk about the fact the whole setup shouldn't be more than a few thousand. I mention, I've easily already spent that over the last five years trying to save that money and have nothing to show for it! I should have just gotten the jetsurf and enjoyed myself all these years. I know that most of the fun has been in the garage, but I won't admit that. I think that is why the ebikers are perpetually building new bikes. It is a way to get your mind off all the other problems in your life. I did the same, the minute I got things working right on one of my projects, I'd move on to the next one before I really spent anytime on the finished product. Talking again with him, I decide that even if I do get this efoil working, I'm going to have to find someone to build a board, build a better enclosure, get a waterproof remote, and finalize a carbon fiber foil mast that will have motor mounts. I do have to face it. I don't have the skills for this project. I can barely 3d print, barely model more than a box. I can barely put together a foil. I don't know how to lay carbon fiber.
I don't know how to chop a surfboard in half and fiberglass the ends. I don't have a lathe and can't mill parts out of aluminum. I don't really know the difference between a ball bearing and a needle bearing. I don't even know what foil shape is best. Heck I can barely ride my foil behind the boat.
I definitely can't pump on the second wave. Who am I kidding on this? He says he knows some people that know some people... The same guy needs the Slingshot board back to do some kite foiling and I'm out of luck. My foil board is stuck in my boat a few hours away, and I'm not getting down there for another month or so. The lake where my family goes is almost empty and has some algae bloom making it unsafe to swim. No more wakeboarding, wakesurfing, or wakefoiling this summer. My kite bladders are even all blown out. Not that we have any wind this time of year either. Ouch! (Still have some fun ebikes though!)
A month or so later, and a few thousand emails, my buddy's contacts send us the board. Just in time for the weather to change for the worse. The season pass is already bought, a new snowboard ready to be waxed. It's the real deal though this efoil, a carbon fiber foil similar to the Slingshot Infinity I'd ordered after seeing it the first time, which still is on backorder. A giant 40Ah battery. A board with a waterproof deck lid, enough space for the controller and battery. The motor, close in size to the Boma but waterproofed with a protective duct and a four blade prop. It had a battery gauge I could see built into the board. None of it 3d printed, none of it that looks like it was made in my garage. My first attempt is heavenly, almost surreal. I've ridden the jetsurf and it was kind of a nightmare. A pain to water start and harsh on my legs and feet. This was different. No chop, felt like riding powder. I was riding on electric power with nothing but a hint of noise from the motor and the rustling of the wake I was making. I rode solid for an hour. My legs sore and stiff from trying to keep up on foil. I'd fallen a bunch and it had taken some getting used to, but it was great. As I am taking the board apart on the beach the sailing crew that was out there kept coming in to take out their boats. Thinking I was hot stuff on the beach, e-foiling, first in the state and all that hard work and effort. How cool must that have looked? A couple of them mention they never saw me get up on foil, doesn't it work they ask. There goes my ego! I want to yell, you try this thing. Its not easy, and plus I was foiling, just would rather crash from a foot out of the water than 3.
But, after all the years, it was sweet. I've been out about ten times in the past few weeks, even with temps getting cold. I remember Hiorth in a Santa suit and tell myself to toughen up. We have had some issues with the board. A remote that wasn't exactly waterproof - which who knew. A foil, like Lift that had too much flex and cracked. All in all, everything seems to work. It should, it is electric. No mixing gas, no clogged carb, no bad plugs. As long as the controller doesn't catch fire, or the battery has issues,then we'll be in good shape. The thing should last for years. I'm done with projects for a while. I do feel like I've cheated, especially seeing all the effort and hard work that has gone into everyone's builds. Finally it's time to ride!
Now for some pics.
              ![20180918_162643|690x388]

https://www.youtube.com/watch?v=s4QURUBh3lA
I will update links when I can.