Simmons Gen III"s cut out

[christopher]

After only a 5 month delay I finally got this little project done and off my list!!


This is our patient.
The tail end of the Simon Flexi Ski, Gen III

I started off by measuring back 1 inch from the mounting plate and marking the side wall of the ski

Then coming IN 1.5 inches from the side wall and marking a 2nd line.
This is APX. the location of the keel on the underside.

And I marked the line all the way to the tail end to follow with the Jig Saw.

 

[christopher]

Flipped the ski over the made the same mark on the bottom.

And traced out the appx. radius curve I wanted to follow.

 

[christopher]

Picked up a new jigsaw for today's project.
NOTE.
Having a SCROLLING JIGSAW came in REALLY handy when I discovered that I could NOT get the foot in close enough to the Keel to make the final radius cut...

Totally LOVED the little laser it came with.!

First cut come straight in to the Keel edge.

2nd cut was down the length of the ski

You will notice a 2nd white line in the above photo.
I traced TWO lines on the ski.
The 2nd line was where I "Thought" the cut would "Look" better, and I had considered going back and making a 2nd cut after the first measured trim was done. But in the end, I did NOT use this as the location of the Keel on the bottom of the ski completely controls where the cut has to be made.

 

[christopher]

The only hard part about this project is making this radius cut.
I blew threw a few blades on this trying to figure it out.
In the end the SCROLL feature solved the problem!

File, File, File and then go back and FILE some more!
I used several different files to round the corner out and then to smooth all the sharp edges on the entire length of the ski cut.

 

[christopher]

One you finish filing all this plastic down, then its time to heat it up a little and really smooth it out.

1 Propane torch.

Ran the torch back and forth many many times.
Getting it just hot enough to get soft, but NOT to melt of run.
Reminded me of my days working in a ski shop doing tuneup on downhill skis. Gotta just love that smell!

Nice and SMOOTH!

 

[christopher]

The finished product.
Total time, about 1 hour for me.
Probably less for someone that knew what they were doing in advance

 

[SoDakCat]

Good Job on doing a writeup on this. You could have done your curve easer. Just use a hole saw to make the bend first and then just cut up from the end and side to line up the side of the curve with your cut. Thats atleast how I plan on doing mine.

 

[nikeholley]

Well...

Good Job on doing a writeup on this. You could have done your curve easer. Just use a hole saw to make the bend first and then just cut up from the end and side to line up the side of the curve with your cut. Thats atleast how I plan on doing mine.

That there's a great idea..!!..

Nike

 

[christopher]

Good Job on doing a writeup on this. You could have done your curve easer. Just use a hole saw to make the bend first and then just cut up from the end and side to line up the side of the curve with your cut. Thats atleast how I plan on doing mine.

DANG!
That is an EXCELLENT IDEA!