So... We are creating an online tool that will track every splinter of bamboo and every drop of epoxy. We will deliver images and words when a step in manufacturing of ones Grace ski is complete. We will no longer expect full payment but a down payment option. 50% to start the process and get "in line" or as Matt would Say the "que" and 50% before delivery/shipping. We will promise a ski in no more than 30 days from initial down payment. So...
To make your ski here is quick and very simplified list of what we go through to make a Grace Ski...#22 is the best part....
Bases and sidewalls:
We water jet cut our UHMW PE bases and sidewalls, this is the most accurate way to create these pieces. Many start up companies referred to as "garage brands" use jig saws etc. We have these in stock wter jet cut to .001 tolerance.
We have these in stock. We use a CNC or a computer numerical controlled router to rout our bamboo cores. We design the ski in 2D CAD software, export it to a 3D software to produce a 3D model. The 3D model is then translated to the CNC machine to cut the shape from stock vertically laminated bamboo core blanks. If a custom flex is discussed we CNC a bamboo blank to those specifications. Our tolerance on the CNC is .001".
Tip and Tail Spacers:
We have these in stock. We cut these to size per ski. In each ski there are two 2mm thick UHMW PE spacers, one in the tip and one in tail. We prefer this so the bamboo core is not exposed at the ends of the ski. Simply more durable.
We have these in stock. We use a 1.8MM edge or as the industry calls it a profile 129. Cold rolled high carbon steel...
Fiberglass, V.D.S. rubber and Carbon:
We have these in stock. The application, weight and length are all cut per ski and specification.
We have this in stock. MAS Epoxy.
1. 50% payment received
2. Custom flex/composites and top sheet art is discussed if applicable (10 days for collaboration and final design agreed upon)
3. Attach edges to base.
4. CNC core
5. Align core with edge/base composite with internal pins.
6. Epoxy water jet cut sidewalls to CNC'd core (if a core is custom cut we need to customize the sidewall to match within .0155" tolerance.)
7. Laser burn top sheet per customer
8. Apply System III to top sheet post burn
9. Attach tip and tail spacers to core and sidewall composite
10. Lay up ski. Base/edge, fiberglass, carbon, core/sidewall/tip and tail spacer, fiberglass, laser burned and system III coated bamboo veneer.
11. Press lay up at 50psi. (time depends on layup composition and temperature in press)
12. Allow a minimum of 3 days for full cure post press. Rest the ski, no flexing etc
13. Band saw the "flash" away from pressed composites. Flash is the extra epoxy and fibers that squeeze out of the ski during pressing.
14. Sand tip and tail
15. 90 degree rout edges to eliminate epoxy from metal edges.
16. 22 degree rout to create sidewall profile.
17. Remove all protective tapes
17. Tune bse and edge with 80 grit belt
18. Tune base and edge with 100 grit belt
17. Apply second and or third coat of System III/sand or texture as specified
18. Stone grind to specifications.
21 and 22 are up to you unless we make other arrangements...
21. Mount with appropriate bindings