The Fliteboard eFoil thread - Info for the DiYer

How is assembled a Fliteboard ? How do they create
1- a solid link between mast and board ?
2 - a direct thermal bridge between the mast (permanent passive cold source) and the ESC ?
3 - a solution that offers the shortest possible wires between ESC and motor ?

A first document unveils a few interesting details: Fliteboard patent - Module for Connecting a Mast to a Board
A second document about the battery case that was registered last May should be published in 8 months (Early 2020): Fliteboard patent - Battery enclosure

At Fliteboard and probably among competitors, an eFoil board is nothing more than foam added around a large and rigid waterproof box with ribs :
Waterproof%20box_s

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First I thought that this passive cooling was underestimated. Then looking at the differences between the Fliteboard patent (Nov 2017 see above pict) and what it is today (June 2019 see pict below with extra cooling fins on alu box AND on mast plate) I thought that the thermal brigde field tests had proven the thermal bridge to be not so effective ie mast cooled section / plate section to cool down = too low = 20% max :slightly_frowning_face::
Time will tell…
@Peter, do you think that your DiY solution without cooling fins could stay below 60°C at 35 kph ? A hybrid solution like a bilge pump cooling down an ESC over the mast is:
1- out of the application field of this pattern (so free to use for everyone)
2- IMHO the best KISS hybrid cooling solution that allows to keep the water out of the battery box and that still shortens the cables between ESC and motor

flightbox-1

Don’t want to be negative but think it is incredible that one can get a patent for this type of design, kind of hard to see what is really a new innovation, looks more like a move for blocking competition. On the other hand getting and maintaining a patent is probably a rather expensive story so everything comes at a cost in the end.

On my first build I used a large heat sink which protrudes from the bottom of the board. You can see the fins just forward of the mast. Really effective thermal management. ESC is mounted to an aluminum plate in the hatch. Only issue with Fliteboard is hitting something and breaking the mast from the board. Nice idea though.

How easy was it to glass the aluminium in? I might have to go for this on one build.

it’s really easy. I used play doh. to make a dam around the area, to not have epoxy run. I used Medium twill carbon fibre just like using fibreglass cloth for strength. Glass in both sides and use heat transfer silicon paste to mount an aluminium plate. My ESC never gets above 85F.

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Do you have a link to the heatsink you used by any chance? Or some close up pics inside and outside.
How did you isolate it so that it does not melt any foam?