Some photos documenting the process I used to build my own pair of downhill skis. Enjoy!

1.
Wood Glue
Poplar and Maple
Wood Strips
Figure 1; Wood Core Materials
Figure 2; Gluing Up the Core

2. Design
Mylar
Edge Profile
Transferred to
Core from Mylar
Figure 3; Planed Cores Prior to Shaping and Profiling
Figure 4; Shaping the Core Edges Prior to Adding Sidewall Material

3. Router is Moved Side to
Side Down the Length of
the Rails to Remove
Material and Shape the
Cores
Adjustable Guide Rails
to Customize Core
Thickness Profile
Figure 5; Profiling the Core Thickness with Custom Homemade Router Fixture
Figure 6; Side Profile View of Router Fixture

4. Router Bit
Figure 7; End View of Cores and Router Bit
Vinyl Maple
Sidewalls Wood
Poplar
Wood
Figure 8; Close Up View of Finished Cores with Tapered Thickness ‐ Thin Tip Region Shown

5.
Figure 9; UHMWPE Base Material, Cut To Shape
Figure 10; Forming the Base and Metal Edges on the Mold
Figure 11; Metal Edge Formed and 'Super Glued' to Base

6.
Figure 12; Vacuum Test of Mold
+/‐ 45 Glass 0/90 Carbon
Fabric Fabric
Epoxy Resin
Application
Tools
Clear P‐Tex
Top Sheet
White P‐Tex
Tip Spacers
Figure 13; Layup Materials

7. Epoxy Resin
Figure 14; Start of Ski #1 Layup
Figure 15; First Layer of Carbon Reinforcement Atop the Base

8.
Tip Spacers
Figure 16; Addition of the Wood Core and Tip Spacers

9.
Figure 17; Adding the Glass Layer Atop the Core
Figure 18; Final Layer of Carbon and Clear Top Sheet

10.
Figure 19; Ready for Vacuum Bagging
Figure 20; Vacuum Applied To Remove Air and Consolidate the Materials

11.
Figure 21; Demolding the Ski – Top View of Tip
Figure 22; Demolding the Ski ‐ Bottom View of Tip

12.
Figure 23; Deflashing the Ski – Metal Edge Used As A Guide
Figure 24; Finishing the Ski Edges

13.
Figure 25; Finishing the Ski Edges – Close‐up
Figure 26; Finished Ski #1

14.
Figure 27; Ready for Ski #2

15.
Figure 28; The Real Test

16.
Figure 29; Success!