“What we came up with is a construction that is better than any other wave kiteboard on the market today.”
50K closed cell foam
It all starts with the core and every board we make starts with
a foam core of our very own 50K closed cell foam. This foam is formalized exclusively for us, it is not used in any other board in the market.
The foam can withstand 50.000 kg per square meter, while staying very light, and most of all very flexible. Another plus of our 50K foam is that it is closed cell, meaning that the foam will not take in water, and the board will not blow out when it gets hot. Any small crack or ding does not need immediate repair. Eventually a repair is advised, but you can first finish your well deserved trip!
50K foam is not easy to shape, all commercially available shaping machines will have great trouble shaping it and hand shaping is not possible. At Appletree surfboards we use our own shaping machines that we built and control ourselves. This way we can not only shape the foam, but we can also create channels and extreme contours, straight from the machine.
From the shaped foam we can go two ways, Hex-skin Carbon or Hex-skin Glass.
Our standard hex-skin construction, consists of the 50K foam core, the core is wrapped in a first layer of structural fibreglass, in a 45 degree orientation. This to keep the board as flexible as possible while making a very strong base. The deck is now layered with a honeycomb layer for more impact resistance. The bottom is left without honeycomb, again to maintain maximum flex.
All normal Klokhouse and Appleflap boards come with a single honeycomb layer. Optionally the glass boards can be ordered with an additional layer of honeycomb, specially for heavy footed riders. Normal use is fine without this layer, but sometimes you want this added durability. This is why ALL BOARDS UPTO 5’5” come WITH the additional layer of honeycomb. Because the smaller boards are used much more for strapless freestyle.
We also use this extra layer to mount optional inserts, because riding with inserts adds a lot of stress to a very small and specific area of the board.
The board is fully wrapped in another layer of fibreglass in the 0 and 90 degree orientation. The whole board, including fin boxes, leash plug and graphics is now pulled in a tight vacuum to compress all the layers together and to pressed onto the core for maximum connection. The board is then encased in the most sustainable epoxy resin available, this resin is tinted to give the boards their unique appearance. There are many colors available and even more on request! You can fully customise your boards appearance so it is unique and there is no one like it anywhere. After the boards are cured, they are hand finished and checked one by one to make sure the meet our exact standards, and you get the board of your dreams!
Hex-skin Carbon is similar in composition to the hex-skin Glass boards. But instead of glass we use 100% carbon fibre, there is no glass hidden underneath the top layer of carbon. Using carbon makes the board lighter and it makes it stick to your feet even better. Because the board is so light, it flows over the chops a lot better than you might expect.
To give the carbon boards their unique look the deck is finished with a tinted resin, that can be customised, pick your own color or mix multiple for a truly one of a kind board.