While I would very much love to do a efoil build my knowledge of electronics is limited so I am just a spectator on that side at the moment. I have however been building foils for surfing for the past 2 years almost. I thought I would post this up as I saw the technique on here and had never tried it but it seams to be working well.
im sorry I lost the pics of some of the steps but I will post what I have
First off I 3d printed a full size wing in parts in pla. I suffered a bit with warping on the trailing edge but it was nothing a little bit off epoxy couldn’t sort when I bonded the parts together.
next off I used some packing tape down ether side of the trailing edge to extend it out ( this is important so as it stops the glass sticking together on the trailing edge)
I then wax the entire thing with a release wax, I gave it 5-6 fairly thick coats leaving to dry between and followed with a coat of pva release agent.
Then doing top and bottom separately I laid up 6 layers of 200g cloth with epoxy wrapping around the leading edge and onto the black tape.
After everything was cured with a little trimming of the trailing edge the shell that has now been created can be popped of the 3d print and leave it to be used again.
next up I printed a tube that fits onto my fuz which I wrapped in glass and carbon to give it extra strength and along with a peace of high density foam bonded it in and made sure it was all straight and true.
Then I glassed over the tube and used a cabo mix to bond the trailing edge together.
after that using two part foam I filled the void, I did this in multiple poor’s and with a few vent holes to let any excess out, you do also need to keep a eye on it to make sure it does not distort as the foam expands. !
part 2 to follow