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The only pictures I have of my finished XLPE TR-48 prototypes at the moment are these low quality phone camera shots (below). Shot of the bottoms was taken while at the beach. Surface mount leash plugs on the decks (not shown) were glued on 3 hours before the 2-day drive to the coast. The planshape ...

Made the annual family pilgrimage to the NC coast only to get 2-3’ closeouts.  I was uninspired until Proneman @ Swaylocks (Roger) asked me how the BBs performed in closeouts.  Thought about it and decided I could get some performance info from the closeouts.  I dubbed the 48” BBs “TR-48s“ (Tunnel R...

Shaping this 6-pcf XLPE is/has been a challenge. As I shaped the first, channel bottom model down to 150 grit and started bringing the second, no-channel model down to 150 grit, Doc's (@ Swaylocks) words of wisdom began to echo louder and louder; Remember, perfection is the enemy of good enough. It ...

If you can find it, 1/2” marine Baltic Birch plywood might make good durable ride.

When LED overheads and natural light in the enclosed porch/sun room aren't enough. And you need better rail side lighting.
(masking tape, plastic saw horse and 2' fluorescent light fixture)

Hoof rasp removed enough foam for me to begin final rail shape.
(This is the channel-bottom blank.)

Things were looking like slow going for arm-muscle rail shaping. The 8" wood rasp cut well but was too small. The 10" surform worked but still wasn't going to be too speedy. Then I discovered this 14" rasp at Tractor Supply Co. this morning. Much longer and wider cutting surface, shar...

The shape itself looks like a standard bodyboard. Is it going to have the channel like your earlier photos? It is my basic 48” blank for any shape I might want. It is a slightly modified version of of a template I created using the dimensions from the mid-section of a 5’5” Lis Fish. Original plansh...

Thanks for the input NMTomas, I’m familiar with the properties for a good number of foams. Couldn’t get much specific information about IFoam when I called Marko. Asked if it was Arcel foam (70% EPS & 30% PE). Coby Peterson told me it was “similar.” I’ll have to give Microblade a try. 6-pcf XLPE...

My old handsaw made quick work of removing the scrap-foam tags.
Next, I remove the lip that attached the scrap-foam tabs with a carpet knife.

Picked up my blank yesterday.
This is what I will start with (planshape and nose rocker/kick pre-cut).
I have a lot of trimming to do; then shape the nose, rails and tail.

" This XLPE eliminates the need for glassing." - how is it sealed? Does not need sealing. The XLPE is small-cell closed cell foam with almost no water water absorption. Swimming kick boards are EVA, small-cell closed cell foam and similarly are not sealed because of very low water water a...

Got three blanks back from the CNC shaper this past week — 2, XLPE and 1, EVA. The CNC cut the bottom channel and planshape as well as it did the pink XPS. Lots of hand trimming and cleanup sanding remain. The EVA is too soft and has too much flex — will be a good surf toy for the grandkids to play ...

I'm not sure the flex is ideal. I'll probably go lighter next time-maybe less fiberglass too. The lighter densities of XLPE from the supplier had much more flex than the 3" thickness. I'm surprised you didn't/don't have bonding/delam problems glassing XLPE. XLPE has low "surface energy.&q...

Wow, that CNC shop looks professional! If the material doesn't absorb water or otherwise suffer from use without glassing, you could surf it as a slab and then refine it incrementally as you get real world feedback. It is an impressive shop. And the owner/machine programmer is very gifted. In addit...

I had a meeting yesterday with a CNC shaper approx. 100 miles from my location. This was just a test cut on the fly to see how well his machine could cut complex contours, using a piece of XPS I brought along and cutting files I already have. I will use this cut for experimenting with cork skins und...

Have you made any progress with this material? I’ve also bought some in the same density and man is it difficult to shape. My most effective tool so far is an angle grinder with a flap disc… Not yet. Will be a slow build/shape. Bought some 6-pcf EVA too (see previous post). Also waiting too see if ...

Bought a 3” x 24” x 48” slab of 6-pcf EVA to play with too.
More UV tolerant but a lot more flex — somewhere between a boogie board and an inflated air mat.
A bit softer — so could be significantly more difficult to shape.
Promises to be an interesting/challenging experiment.

You need to try the "Pororoca."

Thanks UncleG.
I'll give Barge Cement a try.