An electric surfboard designed and built from scratch
An exercise in CAD, composites, electronics, integration and scope creep…
Fig. 1
Fig. 3
The whole project started as a self designated CAD skill building project to design and fabricate a jet pump and impeller from scratch. It allowed me to play with and simulate fluid dynamics as well as design molds/forms for custom fiberglass assemblies.
I then constructed the board out of laminated 2” sheets of EPS foam from Home Depot. I used a large homemade hot wire cutter, along with a handsaw, rasp, and sand paper to shape the board. Rigidity was added with a ½” plywood stringer.
The electronics housing, made largely from laser cut acrylic/3d printed components was then installed. Water cooling lines were run between the coolant inlets/outlets in the housing and the inlet/outlets of the pump unit to provide active cooling to the battery and speed controller
Fin-boxes were then installed to support standard FCS surfboard fins.
Unfortunately for everyone this is the only documentation I have of the fully assembled pump unit. The two halves were molded (fig. 1) and then joined/ faired together. Two flanges were then added on both the inlet and outlet with acrylic for shape and fiberglass for rigidity.
The pump unit was then installed and the board was wrapped in fiberglass. At this point the board was functionally ready for electronics.
Close-up of current electronics housing/components
Fig. 2
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