For the last couple of weeks we've been working on coming up with the best method for laminating our cores. We started by gluing one of them up, but ended up with it warping pretty badly. The clamping method that we used for that core can be seen in this photo: http://picasaweb.google.com/skiingfreak/SkiBuilding/photo#5129552177868870930
We more or less ran into 2 problems with the method we used...
1. The clamps pulled up on both sides of the core causing it to have a little bit of a concaved shape (kind of looks like a very soft "U" shape as you look down the length of the wood in either direction. This likely could have been prevented with this clamping method by also clamping the core down instead of just clamping it together...
2. When we glued up the core and clamped it, a lot of glue ran down between the strips and pooled up at the bottom of the core. I think the effect this had was to allow the top of the core to dry faster then the base. This caused the top to contract while the bottom stayed at a full width.
And oh, just so everyone knows, I think clamping the skis directly on top of a tarp is probably a pretty bad idea. While the glue didn't stick to the tarp (that was the intention) it also didn't dry until i took it off the tarp.
We came up with a couple of different methods to try on the next couple of cores. One using bar clamps and another using the same method we did before, but using painters plastic so it can lay nice and flat, as well as clamping down the strips. Last night I decided I was just going to give it a run with the bar clamps. I think it's probably the easiest method and it was late, so I just rolled with it. Here is a shot of that method: http://picasaweb.google.com/skiingfreak/SkiBuilding/photo#5129573940468159826
Well, the core turned out great. It will take a little bit of clean up to get it nice and flat, but that will probably be the case no matter how we do it.
To get a nice flat surface to work from, our plan is to make a couple of straight rails for our core profiler table. This way we can use the table to mimic what you'd do with a planer to get a smooth surface. Our second core is in the clamps right now drying as I type this. We're likely going to glue up the other two cores this week and hopefully be profiling our cores within the next couple of weeks. Here is a shot of the first core, fresh out of the clamps: http://picasaweb.google.com/skiingfreak/SkiBuilding/photo#5131784561736797410
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