How to Build a Hydrofoil: Overview, Planning and Design (Video 1/15)
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- Опубликовано: 16 июн 2024
- An in-depth video series for how to build a hydrofoil from home that actually works. There are several ways to build a hydrofoil, this is simply how I like to do it. - Free Hydrofoil plan here: flukeskitesurfing.com/hydrofo...
- Find Recommended Hydrofoil parts here: HydroFoil Parts Here: flukeskitesurfing.com/store/c...
This video covers the overview of How to Build a Hydrofoil. The goal is to cover why the hydrofoil is designed the way it is, including the key fundamentals of building a Hydrofoil that actually works. That includes principles of hydrofoil design that are built into this Flukes hydrofoil DIY3 design that helps anyone make a hydrofoil while also allowing modifications of the plans. We also cover what materials we use to build this timber core hydrofoil and explain the free hydrofoil plans available for download, which include cut out the templates.
We cover modifying the plans. You can use this design to build a hydrofoil for Winging, Kiting, Towing, SUP, Surfing etc.
The answer is yes if you're wondering if you can make your own hydrofoil from home :)
This is the 1st video in the series of 15 videos. We hope to see you in the next one and that you find it helpful!
Video Chapters:
0:00 - Introduction
0:26 - Flukes Foil riding clips
2:27 - Concept Overview
7:25 - Foil Section Design
9:23 - The Fuselage
16:34 - Foil Wing Cutout Templates
17:29 - Materials and Cost
20:53 - Modifying the Design
THE FLUKES HYDROFOIL V3 CONCEPT:
The Flukes DIY-3 Hydrofoil is designed based on proven hydrofoil principles that ensure it will fly while also focusing on simple manufacturing processes that make it accessible for a DIY home project. The plans outline the dimensions for building the Front and Rear Wings and the Fuselage, to then be connected to a production aluminium mast.
Foil design plays a critical role in the foil's lift, speed, stability and maneuverability. Understanding that no individual foil design can best perform in all flying conditions, and a home-made foil will never be as refined as a production foil, the intention with the Model DIY-3 was to build a "all rounder" foil with a solid Fuselage and strong connection points that people can use across various disciplines and skill levels. The plan dimensions can be scaled up or down to adjust the wing size that best suits the discipline and rider should they choose to do so. Disciplines include; Kitesurfing, Winging, Surfing, Towing, SUP and Sail.
This Medium aspect foil is suitable for beginners through advanced riders. While different aspect ratios have recognizable benefits, the medium aspect is a good DIY starter wing. This foil Lifts smoothly, handles speed well and feels stable underfoot. It is a fun design to make and use.
Hydrofoil Construction:
Hand-shaped solid wooden core wings laminated using epoxy resin and multiple layers of 6oz Fibreglass and Carbon fibre.
The design features flat bottom wings in both the profile and cross section of the wing. The flat foil design significantly reduces the processes and skills required to construct the hydrofoil wings, and it can be handmade from start to finish. (Without the use of a CNC or vacuum bagging)
The use of a solid extruded aluminium flat bar fuselage further assists the construction by minimizing significant errors that could occur. The wings attach to the opposing sides of the parallel aluminium Fuselage, so an appropriate angle of attack for flying is automatically obtained. This will create a hydrofoil that flies, even if the production of the wing shape varies slightly from the plans.
The Fuselage is drilled and attached to the wings using high-tensile Stainless Steel screws. Holes are also drilled to connect to an Aluminium Mast of your choice. In this case, specified to fit the Flukes Kitesurfing Production Aluminium Mast (and others that use the same M6, 40mm spaced drilling set-out)
A benefit of building the Fuselage in this way is to attach it to different lengths of production masts for different conditions, as well standardize the drilling layout to attach various wings to the Fuselage should you decide to build more wing shapes/sizes in the future.
1. Design Principals • How to Build a Hydrofo...
2. Cutting outline • How to build a Hydrofo... 3. Shaping • How to Build a Hydrofo...
4. Resin Sealer coat • How to Build a Hydrofo...
5. Glassing • How to build a hydrofo...
6. Resin filling
• How to build a Hydrofo...
7. Top Lamination • How to Build a Hydrofo...
8. Resin "Hot Coat" • How to Build a Hydrofo...
9. Final Sanding • How to Build a Hydrofo...
10. Drilling Holes • How to Build a Hydrofo...
11. Fuselage - Shaping • How to Build a Hydrofo...
12. Fuselage - Tapping Holes • How to Build a Hydrofo... 13. Fuselage • How to Build a Hydrofo...
14. Assembly • How to Build a Hydrofo...
15. The Test - Riding The Foil For The First Time. • How to Build a Hydrofo... 
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This is what I have been waiting for since the first videos on RUclips about hydrofoils. I will definitely make a project according to your drawings. Hello from Ukraine!
Great video. One of the best explanation videos I’ve seen.
Awesome! Thanks
THIS IS GOLD!!! Thank you so much for all of the work you put into this, and making the plan sheets Free makes it 100 times better. Thank you so much.
Awesome! Yeah mate happy to share :)
Thanks for doing this, appreciate the sheer amount of effort that must’ve gone into everything you’re showing. Been trying to get something like this started for years and you’ve just gone and simplified everything. Looking to kite and e-foil eventually. (Sunny coast, oz)
Awesome! Yeah mate this was a big video project haha! I enjoy it so happy to put it together. Hopefully is helpful! :). Keep us posted on how you progress with it!
This is the most well put together and helpful guide thank you very much
No problem! Glad it helps
Fantastic series of videos Luke. You’ve got me motivated! Just worth mentioning that if you want to scale the design to increase area by, say 20% to 1.2X the original area. Then the linear dimensions should be increased not by 1.2 but by the square root of 1.2. That is 1.095 or about 1.1 I.e.+10%. This is because if the length is increase by 10% and the width by 10% the area will be increased by about 20% 1.1 x 1.1 = 1.21. Thanks again for the major effort that you’ve put into this series
Hey Paul, yes really good point there for anyone reading the comments thats how it should be done! Thanks for the detailed comment!
Stoked to hear the series has you motivated to build a foil! :)
EXCELLENT, Excellent series! - I binged watched the entire series. I'm in my 60's and want to make some of these and found this to be a perfect fit. Although, I've just started my research on RUclips, I've either run into DIY people that didn't really seem to be expert users and thus I really didn't trust their design decisions. Or... they're expert riders and were talking about finer points only experts can appreciate. You have successfully blown out both groups by being an obvious expert rider, expert builder in your industry, but willing to make the educated/experienced compromises to simplify the building, without sacrificing usability... especially for the beginner to intermediate crowd!
I have tons of questions that I'd like to pose related to how to tune the design for my age, skill level, weight and area I want to explore (E-foiling to start with). Although, you suggested just "Googling it" on several points, it sends me back into the fog of who to trust. You have established a high reputation with me... "He means that he feels safer about your guesses than most other people's facts." (Star Trek IV)
But for now... would you consider doing a series like this on making the board?
oh perfect mate! Thanks for the comment :) stoked to hear the info is coming across well and you watched it all. And yeah, I do plan on making a how to make a board video too... should really do that next as I plan on making one anyway :)
Currently in the process of making the foils. The mast kit is amazing. The whole series if well done.
Awesome! Thanks for buying the Mast kit! Stoked you like it :)
Luke, this is brilliant! I built a couple wood foils, first from a modified Clearwater kit, and then different size masts and front wing. (I learned to foil using my wood foil bolted onto my homemade plywood twintip board.) Probably the most difficult part was getting the mounting surfaces of the fuselage to be parallel and square after glassing, using hand tools in my garage. It took a bit of work to get the front and rear wings on the same plane. You've avoided that problem with the aluminum fuselage and mounting to the upper and lower surfaces of the stock material. (Then the part that doesn't matter can be cut away without any precision required.) Brilliant! So the only thing required is the mast and base plate, which I see you are now selling for reasonable prices. Excellent! It's fun to experiment with different size wings for surfing and wake foiling. I've had lots of friends and family get up on a foil and love it. (even when they had trouble getting up on a wakeboard.)
Awesome thanks! I appreciate the comment. It's good to hear from someone that has had experience building hydrofoils before, because you understand the importance of key points of the design to make a foil that actually works with perspective on just how difficult it can be so thanks again :)
It sounds like you have the skills to build the foil in this series which is awesome, but after making this foil i was thinking... maybe I should make a super DIY friendly version for the series that uses much less tools.. The same foil could also be built with a foam core and an unshaped alloy fuse. Wouldn't be as good... but would still work for somones first attempt. Anyway... lots of ideas haha :)
Yes, it could be simplified a bit more. I didn't have access to a planer and a table saw when I built mine. But it's totally possible to do with hand tools only. I don't know if a foam core would be easier or harder. Easier to shape, but also easier to mess up the mounting surfaces and the symmetry. Wood is such a good material (God's great composite) to work with, and if you use a lightweight species, adds stiffness without too much weight. I'd love to get some Paulownia or Balsa to build a foil!
I bought ur Plan.
Thank u for ur video .
I will make this. 🎉🎉🎉
Awesome! Have fun with the build and let us know here if you have any questions!
Awesome you are the professor bring it on
Haha nice let us know how it goes :)
i cant wait for the next video nice way to start 2023 by the way ❤🔥
Perfect! Yep start they year off with a project! :)
Thanks got the plans
Nice! Let us know how the build goes
Thanks!
No problem!
Awesome. I have a 5 gallon bucket of resin that is past it’s shelf life but I’m pretty sure I can get it to kick. Need to make a few things to burn it up. New to kiteboarding and leaning solely on videos. Fun project
I know you used epoxy but I can’t see why my VE resin won’t work
Perfect! A fun project for sure!
yeah thats right, epoxy is not necessary, it is just the Resin I like. But if you already have some resin, definitely use that :)
MmaaaTtee,,,, that was Awesome Video, very Informative, Grrrrrrrrrrrrr8 Work loved it, I'm into water skiing, have an Old School 350Chev Inboard & Our Boat doesn't make a big enough Wake to be able to Wakesurf,,,, Yes I know there's the Option of on board Balast Tanks, but I definitely don't want our Boat any lower in the Water than I already is, so I want to DIY a Wake Foil & see how We go from there, buying one is just way out of reach 4 us,,, thank You & well done, I'm going to use Your Information to the best of My Ability,
Nice keep us updated with the build :)
Hi,
Awesome info, I will definitely put some workshop time in,
Does this foil design work for a surfboard as well, ie. Completely reliant on arm paddle power to lifting up in the swell and/or wave?
Hey Van, epic! Let us know how it goes. The foil will fly for surf for sure. you might just need to tune the size to suit you.
Also, i haven't tested it for flat water pumping so i cant say how well it will work for that :)
Hola Luke soy Miguel desde argentina, santa fe.
La verdad me ayudó mucho con los planos que compartiste, lo hice con alas de madera y el fuselaje de aluminio macizo tal como lo hiciste tu. Me falta laminar con fibra. Y la verdad me gustaría mandar fotos estoy muyyyy contento. Ya que en argentina estamos pasando un momento muy malo económicamente y es muy caro comprar un foil. Desde ya muchas gracias un abrazo
Hi there. Thanks a lot for this valuable content.
A question: as you mentioned, not everyone will have the tools and skills for wood work. For instance, in my case, it would be easier to build the wings using a 3D printer. I'll try to convert your plans to a 3D model and make it available on thingiverse but if you don't mind to share the DXF file, it would be easier since I wouldn't have to extract the wing's curves from the PDF files.
Hey Renato, That would be epic!! I'm not entirely sure how the 3d printed wing would go for weight and size constraints, but it's a cool idea for sure and would be stoked to hear how it goes. Unfortunately, I don't have the file in DFX as I do everything on my mac and not adobe so I am unable to help you with the file, but I did want to say, most people that might find the woodworking part hard, could either use plywood (so they don't need to thickness the wood) or foam as the foam is easy enough to shape just with sandpaper. You can follow the exact shaping design process with foam as outlined in the video series if that would suit you.
Fantastic tutorial, many many thanks. Just one point someone might help me with. Im big and need more surface area for winging. To keep it simple, imagine i need 2x the surface area of the hydrofoil shown here. If I just double the linear measurements I think I'll end up with 4x the surface area. Am I right in thinking that to double (x2),the given surface area, I'd need to upscale all the linear measurements by the square root of 2.....IE 1.414. If the front wing was a simple rectangle, doubling its width and breadth would I think quadruple the surface area. Im definitely going to build this hydrofoil thanks to the amazing time and effort put in by Flukes, but I want to be sure.
Hey Pennina, yeah that's right. If you simply double the dims it will 4 x the surface area, and your 1.414 is correct. If you are using the download template, there will also be variations on printing paper, even download/print resolution might change the finished size, so also keep an eye on the actual length width etc. I'm sure there are also surface area calculators too, but I do it manually, so there would be a +/- variation in my calculations (just in case you need it to be perfect )
Great video!
Do you think that 3D Printing the structure of the foil would be a good option?
Hey Daniel, I haven't see anyone do that, although maybe they have.. I would be interested to hear how that would work if you do try it! :) How much do you think the core would weigh? and you would need a big enough one to print the front wing?
@@FlukesKitesurfing the weight should not be that much, since the infill of the print would be around 20%-30%, I am thinking of dividing the wing in 3 or 4 parts and then glue it together. Hopefully it will work :D do you happen to have 3D files on you hydrofoil?
I can see a foil built with a similar technique than hollow boards, printing ribs (with foam fillers) or a desktop CNC using either wood or foam core...
I agree with Daniel and will be 3D printing the cores for me. If CAD'd properly, the plan and foil shapes will be near perfect and symmetric! HOWEVER, you would have to compensate for the lost strength (wood to plastic change) by increasing the fiberglass layers. In example... If you cantilever a piece of the recommended wood, you could easily stand on the end. It's strength is quite significant! In plastic, you'd be lucky to load it with ten pounds. You'd also need to compensate for the added skin thickness in the CAD foil shape. To save weight, you might have say... 10 layers at the root down to 2 layers at the tips... again... making the CAD more problematic.
Hi, thanks for this, it sound like a cool series of videos !
I have a few questions:
- do you have a rough estimate of how long it will take for a total beginner to build this (since money is not the limiting factor here, I'm guessing effort/time is probably the major one) ?
- can this design be used for dockstart / pumping ?
I think you want a pretty big wing for pumping since in kiting you’re getting heaps of power from the kite which allows them to be small
Hi Oliver, for sure :)
1 - exactly, this is low material cost but does take some time to build. The foil takes me approximately six days in duration, but only a couple of hours each day as it is more about letting resin set than it is hard labour :) It will be clear once i get the other videos up.
2. The simple answer is yes, but pumping does like particular foils that are more efficient. Typically a higher aspect ratio is better and potentially a bit bigger. as mentioned in the video it would be best to google what size might suit you best for that. Id suggests you can keep the rest of the design, follow the production techniques, and simply change the size/shape of the front wing. Hope that helps
Yeah for sure. :) This 866cm is a size that can crossover as its a bit on the bigger size for kiting
@@FlukesKitesurfing Thanks for your answer !
Can't wait for the rest of the series !
Hey Luke, how do you resize proportionally? Do you have a program or how do I have to imagine it in practice? it would be best to have a template for the form to print out. Thx for answer, Jürgen
Hey Jurgen, to scale the plans, there is no program to do so. But you can do 2 things.
1: is to plot the new dimensions on a sheet of cardboard manually. I think I do mention that briefly. That's how I have always done all plans (except this one). You simply scale all the dimensions for the size and wingtip curve dimensions, then draw a rectangle on the card, then plot the dimensions dots, the connect the dots with a curve (bending a thin piece of wood.
2. You could also try and scale the cutout templates before printing. To do that I would open the pdf, then zoom in or out to the size you think it might be. Screenshot that, and then print that. It would be hard to know exactly how big it will be until you print it, but that would be a way to easily make it slightly bigger or slightly smaller and still be able to use the plans cutouts. Hope that helps
@@FlukesKitesurfing Hey Luke, thank you for the valuable and detailed answer. I'll just try out both options and see if I can implement it well. Best regards, Juergen
@@juergensplieth6068 For sure :)
I have a rather complicated question...I'm designing a small craft that i would like to steer by way of the foils. So if i split the front and back foils into left and right articular movements, in your expert opinion could you for-see actual steerage?
Thats a great questions and i'd love to hear how it goes when you complete it. I have never tried that, however you would presume it would roll, but i don't have the experience to tell you if it will bank. You may be able to find the information in aero engineering as planes must be doing what you describe. Keep us posted :)
Hi, what is the minimum speed to take off and the total weight of set (rider+board+hydrofoil)? Thanks.
Hey, ill try and answer some of the questions for you :)
Speed: I haven't measured it not exactly sure, but pretty slow, similar to jogging.
Foil mast set: 3kg
Board: 2.5kg
Rider: 77Kg
Hope it helps
hello thank you very much for all his well derailed video.
when I want to recover the diagrams the site offers me only three (the first three) is this normal.
Hmm, not sure what you mean? it's not downloading?
Make it a playlist.
For sure Alex! As soon as its all uploaded. Big job this one :)
look into the kayak market to power them cost 2 times more than buying it ,,,can you help the old guys out ? i have everything figured out but the foil,,,,,,,,please help
There are any 3d print sketch for this wing?
Yes another viewer sent them to me, if you email via our website ill send them to you.
can you work with me to get a 75 lb kayak lift with an electric motor ?
Will it work without the flying thing?
It needs all parts to work :)
so 75 lbs plus 300lbs rating ,,,, a 75 lb kayak and 200 lb person ,,,,your foils fly and i will build them as a partner, but as myself, I am old and love to fish but do not want to paddle across the lake,,Can we do this ?
Think about it ,(help out grandpa )
20% increase in dimensions will add much more than 20% in surface area...
Yes, the you have to use the square root if you want to find a particular increase in square cm :)