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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Thinking about tinkering around with building a new strapless toy? Have some feedback about construction, materials, rocker line? Post it here.

Moderators: Lonny, Todd, JonModica, tungsten

Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 7:40 pm

I'm still searching for my favorite board (who isn't), and of course the new favorite has to beat the old favorite. Now my old favorite is a 5.3 x 18.5, flat rockered, skim / surf bastard which works a treat as a skim, with thruster fins, even with straps (I admit it, I'm a sinner, but when it's gusting 15-35kn I mount the safety belts :oops: have to work on my skills I guess). It's a DECAY Scimitar, shaper is from NZ, great board, I have more than 400 sessions on it and it's still awesome.

Just to give you an idea what any new board is up against.

As I said before, McCoy is a surf board shaper with great ideas outside the box, and I wanted to give it a try for kiting. Impossible to get my hands on one where I live, so I had to build one.

I'll say it straight up front: this board comes VERY close to the board I'm looking for. None of the 20 boards I have tried this year (mostly kite surfboards, some surf boards) were anywhere near what I want. I'm riding in messy shore break with light winds half of the time, and that's where the board has to work. No easy task.

The McCoy Nugget 5.3 x 20" has quite a bit of rocker in the tip, but almost any in the tail. It has a strong convex bottom from tip to tail (8mm), as opposed to any other modern board out there. The outline is unusual, with the wide point far back, an with a round tail. I built it half the thickness of the original, which is huge. I came out at 4cm for the best part of the board, thinning out in the tip.

These design features lead to a very stable, very forgiving board (loads of surface in the back), which still turns with ease - I mean really loose - due to the convex bottom. No tail rocker - a really long flat section - is good for low end, and the concave makes it loose enough so you don't need tail rocker. The tip has quite a bit of rocker which is nice as the board does not pearl. I had it out 5 times now, from 12 kn to 20kn to 15kn gusting 30kn, and it was an easy and fun ride all the time. Board is fast. And it's so forgiving. Upwind: as good as my Decay, which is pretty sharp.

There you go, I'm really stoked. I will ride it for some time and probably in spring build a follow-up changing small bits and pieces, fine tuning so to speak. I also handed it out to a couple of advanced strapless riders on our beach, and they went "wow". So whenever you see a McCoy nugget or any of his other small boards, don't let it go. Try it. You will be amazed.

Now, if you (like me) are living far from McCoy land, you have to build one. And here is how:

I started with the same technique as the other woodies, making a plan in AKUshaper, cutting stringer and ribs out of 5mm ply wood, gluing the skeleton together, and covering it with stripes of 3mm ply wood. The light quality in each case, weight counts, and marine ply weighs a ton. Don't use it.

Fill the board with PU foam for strength, sand it to shape, laminate 2x 4OZ top and bottom with epoxy, in go the fin plugs, and you can go for a ride :D That was easy wasn't it?

There are lots and lots of little details in this process. I therefore took some pics to illustrate where I did things differently from former boards. I also found a good link of a very skilled board builder who uses the same technique, but solid wood deck instead. Real beauties, I'll do one like this later on.

Now here's the link, http://nwkite.com/forums/t-12112-0-asc-0.html&sid=fc9aa78260d13d3f4b792f04f0fa34ca

and here are some pics for you. I won't comment much this time, feel free to shoot me any question you have about those tricks and licks.

cheers, tungsten
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 7:46 pm

AKUshaper shots
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 7:49 pm

Rib showing convex bottom shape, which goes all along the board.
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 7:52 pm

Rib master and key/keyhole connexion between rib and stringer
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 7:56 pm

Backbone mounted on a board. A stable mount is important.
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 7:58 pm

Top & bottom strips glued on with PU glue.
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 8:03 pm

Sanded & ready for glassing
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 8:07 pm

My kids love it, my wife says it's butt ugly.
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby Kaito » Thu Dec 17, 2009 8:10 pm

Holy shiiat! BEAUTIFUL Build! Serious skills! :shock:
I have a friend here in Japan that surfs, occasionally kites with the McCoy's & he swears by'm. 8)

Keep us posted on its maiden voyage.
: )
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Dec 17, 2009 8:10 pm

The fins are crap, I will get some decent fins some day, but for the time being that's what I had around.

Hope you enjoyed it. Shoot away if you have questions. If you want to study the AKUshaper file of this board, I'll happily mail it and you can spread it as you please. Would post it here but I don't know how.

good winds

tungsten :D
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby starsky » Fri Dec 18, 2009 9:31 am

Nice build,

How hard is it to shape the rail? Did you end up getting it the way you hoped?

Bet that board is tough enough! the rail end up nice and thick. Thanks for the process pics.

Makes me feel pretty sheepish about riding a surftech!

Two ends of the eco spectrum!
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Fri Dec 18, 2009 9:51 am

Hi starsky, shaping the rail is actually quite fast and not hard at all. It's not hardwood you know :D Shaping the rail does take like half an hour with the planer and another 10 minutes sanding. It is actually quite easy to get the exact shape in wood, takes a bit of effort to remove material and is thus not so prone to sanding in too far.
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby Lonny » Fri Dec 18, 2009 12:20 pm

Tungsten,

Once again, you have outdone yourself. Another fantastic DIY post, and a great addition to the knowledge base here. Thanks again for taking the time to share your passion and wisdom with us here. I would love to give your board a go. The concave bottom shape sounds extremely interesting, as well as the wide point being so far back. Great stuff.
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby decxter » Wed Jun 29, 2011 10:34 am

Tungsten how did the rails of this board hold up? I'm thinking of building this board as my next project but was thinking of using a more traditional surf method for the rails

Also do you have to use the foam or could you get away with it being hollow?
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Build - Rib/Plank Wood Board, McCoy Nugget 5.3

Postby tungsten » Thu Jun 30, 2011 3:45 am

hi decxter, how do you mean, hold up? do you mean the shape or the built? I shaped them harder than surf board rails, which I like better. they are sturdy as, due to a solid 2cm of wood in the rail, if you mean the built. of course you can use a different approach, the original board has round rails.

foam: yes you should fill it with foam, at least under the part where you have your feet. if you want to work without foam partially or fully, you have to add a vent, otherwise the board gets damaged in the sun, on a flight, when cooling down. just more complication.
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