All the sanding pays off! Its time for some Layup testing.

The pair of split molds for the SageSport160 are all wrapped up. We spent a couple of weeks laying up lots of glass on both sides and giving them a balsa core for stiffness.

Once both sides were done and cured, we were overjoyed to find that they both easily popped off the plug when we wanted them too. Note the orientation blocks, this makes the molds much easier to line back up when the time comes.

Once the plugs were removed we once again had some sanding ahead of us to make sure the surface was good.

The finer the sanding, the better they looked. Then we buffed and waxed them….now they look really good!

With the spray booth cleaned up and the molds waiting, we will be laying up the first composite prototype in the next week or so. But before that, we need to test our materials and layups.

With careful study, we have laid up some test panels including the Carbon fiber, Kevlar, and core materials we will be using throughout the SageSport160. Below is a 18″ wide Transom section test, that’s 7/16 thick with 225lbs of lead on it and almost no deflection. A step in the right direction.

Testing continues to find optimal materials and layout. Stay tuned…