CWB Gives us theCheat Sheet forWakeboarding 101

Wakeboards For Dummies

We realize that specialized ski boats command the wake-boarding industry. Names such as Air Nautique, Master-craft, Malibu, and even Yamaha dominate the sport with

boats touting swimmer-safe V-drive propulsion, onboard ballast systems for larger wakes, and advanced hull designs to create amore ideal wake shape – not to mention trick sound systems thatrival some outdoor concert venues.

Personal watercraft often are at the receiving end of wakeboardercriticism and jest, but are rarely given a chance to prove themselves inpractice. With the advent of wakesports-specific watercraft (such asSea-Doo’s WAKE Edition) and fistfuls of horsepower, PWC have consis-tently proved themselves as great platforms for the weekend wake-boarder. Even without a ballast system, the added weight of a spottersitting atop the back seat of a standard three-seater PWC can gener-ate a steeper wake, while trim systems and easily installed ski polesmake towing a wakeboarder all that much easier. The maneuverabilityand economical nature of personal watercraft undeniably make themthe everyman’s alternative to the costly full-sized ski boat.

All grievances aside, wakeboarding is great fun – regardless ofwhat’s pulling you. In fact, we here at Personal Watercraft Illustrated tryour best to sneak in a quick wakeboarding session as often as possiblebetween deadlines. While no one here may be the next Shaun Murray,we love catching up on our skills behind the wake of whichever water-craft we can get our hands on. Further, our enthusiasm for wakeboard-ing got us wondering what goes into the design, production and compo-nents of wakeboards.

To get down to the nitty-gritty on wakeboard design, production andfunction, we contacted Jon Cottons from CWB Wakeboards’ engineering department for answers. Jon graciously guided us fromconception to finish, with CWB’s “Absolute” and “Absolute Platinum”wakeboards.

PrototypingMany versions of boards start as hand-built prototypes for CWB

team riders to try, and are based mainly on the lessons learnedfrom past models. The mastermind behind every board design isCWB’s Doug Cannon, who personally attends each team ride totweak the prototypes where needed. They are hand-sanded andtweaked during the trial process until the team riders find theshape, bevels and rocker that they like. Next, the selected designsand specific details are entered into a computer and a drawing iscreated, with the help of Jon, to be sent to the highly experiencedtoolmakers.

ToolingOnce the drawings are in hand, they are used to create a plug

with the exact dimensions of the approved wakeboard. The precisetooling is created by compressing several layers of aluminumtogether, then cutting a proper-sized cavity from the sandwiched alu-minum. This cavity is then filled with mud and the plug is com-pressed in the mud to form a female mold.

STEP 2

STEP 3

IN THE KNOW

Step 1: CoreA two-part foam is mixed while being injected into a mold. Next,

the foam-filled mold is held under pressure and heat for a shortperiod of time until the foam has cured completely. The mold is thenopened and the hardened core is handed off to the glass room forwrapping.

STEP 1

T E X T B Y J U S T I N S T A N N A R D

P H O T O S C O U R T E S Y O F J O N C O T T O N S A N D C W B

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STEP 2

STEP 3

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Step 2: WrappingOnce the core is in the glass room, a special wrap is

applied. The wrap consists of precut fiberglass and carbonlayers, which add strength and structural integrity whilestill providing flexibility. These fiber layers are stapled to thecore to keep them in place. Then the entire wrap is readyto be molded.

Step 3: MoldingSimply put, molding is a process of applying resin, heat

and pressure to the wrap. First, the wrap is coated with atwo-part resin to seal the board and bond it with the fiber-glass and carbon-fiber layers. Next, it is placed in a pre-heated mold between two layers of material embeddedwith CWB’s current graphics, where it is held under pres-sure to “kick” (cure) the resin. Once the resin has kicked,the board is removed and is readied for finishing.

Steps 4-6: FinishingA freshly molded wakeboard requires a precisely executed

finishing process before it can be ridden by the consumer.

STEP 6

STEP 5

STEP 4First, the rough flashing is removed from the board’s

edges using a band saw.

Then, it is routed to remove what the band saw leftbehind and further smooth the surface.

Finally, every board is hand-tuned to make sure the edgesare smooth, symmetrical and ready for the rider to use.

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IN THE KNOW

RockerThe rocker is a wakeboard’s curve

from front to back. The two mostcommon types are continuous andthree-stage. A continuous rocker carries the same curve from nose totail. Three-stage rockers have twoindependent bends at either end –much like a snowboard or skate-board – although usually not as drastic. The more curved the board,the more rocker it is said to have. Aboard with less rocker will providemuch more control and a fasterride, while more rocker makes theboard feel more loose and gives therider more “pop” on jumps.

FinsThe fins help keep the board

tracking straight in the water andare one of the most highly customizable aspects of a wakeboard. Fin configuration cantransform a board from feeling slippery and free to feeling stableand planted. Molded fins help keepthe board tracking straight, but stillgive it a slippery feel and force therider to utilize the edges of theboard when carving. Most boardsalso offer removable center fins(and outer fins, in some cases),which greatly increase the stability ofthe board for beginners and helpskeep an edge during hard turns. Theability to add or remove fins between sessions enables the r ider to potentially progress from beginner toadvanced, or the abil ity to ride inalmost any condition on the same board.

ChannelsIf you were to turn the board

over, you’d notice channels run-ning from tip to tail. The design ofthese channels – if present at all– are the unique signature of thebrand’s wakeboard shaper, andare rare ly the exact samebetween brands and models.Acting much like long fins, eachchannel performs a completelyseparate function, and can workto determine the overall nature ofthe board. Pros tend to prefershallow channels, because theyoffer a slick feel and good releasefor tricks; deeper channels makethe board track straighter andare great for beginners still learn-ing to proficiently edge.

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BindingsHere’s the tough one. Entire

encyclopedias could be writtenabout binding selection, bindinginstallation and their degree angleson the deck. For the sake of thePWI staff ’s sanity, we’ll keep itsimple here. The bindings are therider’s connection with the board.Bindings now range from super-simple neoprene styles to compli-cated tensioning systems that usesurgical-steel wire and cost hun-dreds of dollars, keeping the rider’sankles and feet firmly planted.Their configuration on the deck isas much trial and error as it isconfusing for the beginner wake-boarder. Most beginners prefer tokeep their front foot angled out-ward (toward the direction oftravel), with the rear-foot perpen-dicular to the board. More advancedriders, however, usually keep theirbinding angles symmetrical – at leastnine degrees out for both feet – tomake for easier backward riding(known as “fakie”).

IN THE KNOW

LengthFactory sizing charts usually dic-

tate which board will work best with arider’s weight and height. However,sometimes going a bit longer orshorter can make a big difference inhandling. For instance, a wake-board that is just a bit shorter thanthe recommended length will feellighter, be more responsive andspin faster, but will sacrifice stabil-ity and can make landing air tricksa lot more difficult. Using a longerboard can smooth out the roughedges and make for clean, delib-erate style, but can be a bitslower and cumbersome to ride.

WidthThe width of a wakeboard will

affect how high it sits in thewater while ridden, and thusdirectly influences how it rides.The width is usually measured atthe center, the nose and the tail.A wide-centered board is greatfor beginners and heavier riders,since they are easier to get up onand are very stable. A widecenter not only sits higher, butachieves more “pop” when jump-ing off a wake, resulting in moreair. The width at the nose and tailof the board generally influenceshow the board turns. Narrow tailsand tips allow for more aggressivecarving and faster, harder turning.Wider-tipped models provide foreasier surface tricks and betterrelease when a rider is throwingspins off of the wake.

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