A thread for customization, chop projects or brand mix & match to encourage development, innovation, DIY and recycling for freeride windfoilers - seeing that the windsurf/foiling industry has mostly abandoned us 
I love the super-stiff Phantasm mast so I've had a few goes adapting it to Axis and Simmer fuses.
Hit something in the water a few days ago and destroyed the mast foot.
It's not difficult to use the fuse as a mould to form a new foot - taped up the fuse cutout with Sellotape to aid release of the cured epoxy.
Cut 3cm off the mast bottom (solid carbon at that point) so that it bottomed out in the fuse cutout, installed the only barrel nut I had and a track nut.
Ensured the bottom of the fuse and mast base plate were both level and the wing was square to the fuse when I tightened the mast to fuse bolts (soap on the bolts to aid removal).
There was plenty of space around the cut off mast to pour in epoxy and jam in heaps of 1cm glass and carbon strands to form the foot.
A couple of hours of curing then removed the bolts and tapped the mast out of the fuse easily. No sanding required.
The fuse cutout tapers to the bottom so the fit is pretty snug.
Pleased with the threads in the epoxy.
Might have missed a few steps so if anyone is interested to do something similar ask away.
Disclaimer - my work definitely isn't engineer verified or production quality so take my advice with a grain of salt - but most foiling projects I've done are still working 
Had a couple of good test sessions in some brutal gusts and so far so good.
Looking forward to seeing ideas and projects from our community 
Great post. I have a decent carbon mast from an "orphaned" foil set that I'd love to continue using. It's a bit thick by performance standards but works well for freefoiling. The two wings for it work but are a bit dated. I wish I had the skills to cnc fuses for it. I know about Stringfellow (here in the US) who does customs but between the cost and shipping the mast back and forth to provide the pattern, not sure it's really worth it.
As well, would love some input on what wings tolerate being "reholed" the best ie have enough structure to fill in the current screw holes and drilling new ones. Like my foil set, just a new wing would be enough to keep it current and usable. My set uses something similar to the IQ type of mount and I'd love to adapt something like the Simmer or SAB wings to it.
Very ballsy JJ,
I remember as a poor college student in the 80's making a Tuttle box mold for a US box Angulo fin.
Very first test the mold broke apart after the 2nd gybe and I found the fin 2 weeks later on an ultra-low tide under a clump of seaweed!
Safe to say my resin engineering skills are limited, but I'll enjoy reading your tests 
My custom mod is a little more prosaic. I installed a twin track foil box in my Predator 110 to fit my new Phantasm 103 wide carbon mast. I purchased the 16 inch foil tracks complete with high density foam box from Fibreglass Supply out of the US. Routing the rebate for the box was reasonably straightforward with a hired router from Kennards. The Predator's deep tuttle box is really strong. Glued in the new box with epoxy and micro balls and 7 Oz E glass. Finished of with more E glass and filler. Just need to paint.
www.seabreeze.com.au/img/photos/windsurfing/21152077.jpg' /> 
Select to expand quotePaducah said..
Great post. I have a decent carbon mast from an "orphaned" foil set that I'd love to continue using. It's a bit thick by performance standards but works well for freefoiling. The two wings for it work but are a bit dated. I wish I had the skills to cnc fuses for it. I know about Stringfellow (here in the US) who does customs but between the cost and shipping the mast back and forth to provide the pattern, not sure it's really worth it.
As well, would love some input on what wings tolerate being "reholed" the best ie have enough structure to fill in the current screw holes and drilling new ones. Like my foil set, just a new wing would be enough to keep it current and usable. My set uses something similar to the IQ type of mount and I'd love to adapt something like the Simmer or SAB wings to it.
Cheers.
Perhaps look at the Simmer 95cm fuse and fit the mast you have to it?
It's inexpensive and has SS helicoil inserts for the wing bolts which is a nice touch.
Your second paragraph - I've redrilled Phantasm, Axis and Simmer foils to accept different fuse hole positions with no issue re. structural strength
Select to expand quoteJohn340 said..
My custom mod is a little more prosaic. I installed a twin track foil box in my Predator 110 to fit my new Phantasm 103 wide carbon mast. I purchased the 16 inch foil tracks complete with high density foam box from Fibreglass Supply out of the US. Routing the rebate for the box was reasonably straightforward with a hired router from Kennards. The Predator's deep tuttle box is really strong. Glued in the new box with epoxy and micro balls and 7 Oz E glass. Finished of with more E glass and filler. Just need to paint.
Nice work - I wondered who would be the first to do that mod.
Curious where you bought the Phantasm mast?
Select to expand quoteazymuth said..John340 said..
My custom mod is a little more prosaic. I installed a twin track foil box in my Predator 110 to fit my new Phantasm 103 wide carbon mast. I purchased the 16 inch foil tracks complete with high density foam box from Fibreglass Supply out of the US. Routing the rebate for the box was reasonably straightforward with a hired router from Kennards. The Predator's deep tuttle box is really strong. Glued in the new box with epoxy and micro balls and 7 Oz E glass. Finished of with more E glass and filler. Just need to paint.
Nice work - I wondered who would be the first to do that mod.
Curious where you bought the Phantasm mast?
Slingshot Sports Australia on the Gold Coast
slingshotaustralia.com.au/
Same as Azymuth to adapt a carbon mast I got for cheap from a kitefoil. Went out a couple of times and no issues.
I assembled the old mast, fuse and wings next to my table, locked them with some weights, made a mark were the leading edge was, then installed the new mast at the same angle and poured in the mix.
Pictures in reverse order
This carbon mast : $350
Naish High Modulus carbon mast: $2,200
Select to expand quoteazymuth said..
Perhaps look at the Simmer 95cm fuse and fit the mast you have to it?
It's inexpensive and has SS helicoil inserts for the wing bolts which is a nice touch.
Your second paragraph - I've redrilled Phantasm, Axis and Simmer foils to accept different fuse hole positions with no issue re. structural strength
Thanks - I think it will be easier to redrill and recast the wings (except the fuse has five screw holes for me to get wrong).
Select to expand quotepowersloshin said..
Same as Azymuth to adapt a carbon mast I got for cheap from a kitefoil. Went out a couple of times and no issues.
I assembled the old mast, fuse and wings next to my table, locked them with some weights, made a mark were the leading edge was, then installed the new mast at the same angle and poured in the mix.
Pictures in reverse order
This carbon mast : $350
Naish High Modulus carbon mast: $2,200
Nice job
Select to expand quotePaducah said..azymuth said..
Perhaps look at the Simmer 95cm fuse and fit the mast you have to it?
It's inexpensive and has SS helicoil inserts for the wing bolts which is a nice touch.
Your second paragraph - I've redrilled Phantasm, Axis and Simmer foils to accept different fuse hole positions with no issue re. structural strength
Thanks - I think it will be easier to redrill and recast the wings (except the fuse has five screw holes for me to get wrong).
Phantasm ptm926 wing off ebay incoming. Hijinks to follow...
First, need to decide which foil set gets the upgrade.
Select to expand quoteJohn340 said..
My custom mod is a little more prosaic. I installed a twin track foil box in my Predator 110 to fit my new Phantasm 103 wide carbon mast. I purchased the 16 inch foil tracks complete with high density foam box from Fibreglass Supply out of the US. Routing the rebate for the box was reasonably straightforward with a hired router from Kennards. The Predator's deep tuttle box is really strong. Glued in the new box with epoxy and micro balls and 7 Oz E glass. Finished of with more E glass and filler. Just need to paint.www.seabreeze.com.au/img/photos/windsurfing/21152077.jpg' />
Cool Mod mate! Was the bottom of that board cored? Any idea of what the lami is or how thick it is? Board building students around the globe are curious That board is the gold standard.
Select to expand quoteutcminusfour said..John340 said..
My custom mod is a little more prosaic. I installed a twin track foil box in my Predator 110 to fit my new Phantasm 103 wide carbon mast. I purchased the 16 inch foil tracks complete with high density foam box from Fibreglass Supply out of the US. Routing the rebate for the box was reasonably straightforward with a hired router from Kennards. The Predator's deep tuttle box is really strong. Glued in the new box with epoxy and micro balls and 7 Oz E glass. Finished of with more E glass and filler. Just need to paint.www.seabreeze.com.au/img/photos/windsurfing/21152077.jpg' />
Cool Mod mate! Was the bottom of that board cored? Any idea of what the lami is or how thick it is? Board building students around the globe are curious That board is the gold standard.
Yes the bottom of the board where the tracks are installed is full sandwich. My guess on thickness of the core is 2 to 3 mm. The lami from memory from outside in was carbon fibre then core then glass.
The Predator is solid, but also light, less than 7kg without footstraps.
Select to expand quoteCoreAS said..
Very ballsy JJ,
I remember as a poor college student in the 80's making a Tuttle box mold for a US box Angulo fin.
Very first test the mold broke apart after the 2nd gybe and I found the fin 2 weeks later on an ultra-low tide under a clump of seaweed!
Safe to say my resin engineering skills are limited, but I'll enjoy reading your tests
Did the same more than 30 years ago,but I found the fin 3 years later diving....??
