Templates

Templates are critical for replication of each ski; they ensure that each ski in the pair are identical. Additionally, once I have the templates I can make any number of skis of the same type. To build my skis I make three templates for each ski. The Core, Core Member, and Base template. The Base Template will be used to cut the base to shape and is critical to the end shape of the ski. The Core and Core Member templates are less critical as the core has several other material removal operations completed after the templates are used. The core template is used to trim the tip and tail of the core prior to pressing. The Core Member template is used to cut the members of the core that are not symmetric. The cores I design are made of 5 members, three of uniform thickness and two of variable thickness. More information on the core design will follow.

To make the templates, I first designed them in Autodesk Inventor. I printed my designs to a pdf. file and took them to a FedEx Office store and had them printed full size. In past years I printed them from my computer and taped them together, but this was far easier, though a bit more costly (~$5 a piece).

I then traced the base template to make the core and core member templates. I used a spray glue to paste them onto the tempered hardboard I had bought.

I then used my jig saw to cut them out.