Customization

One of the unique aspects of the GEARBOX fin system is the ability to customize the load beam's cover.

This customization could be as simple as changing the color to one of our many options, but it can be much more extensive!

There are two different forms of customization: customizing the cover itself and custom overlays. Customizing the cover involves changing the upper surface of the cover or, in the case of HEX covers, filling in the grooves. The upper surface is covered with custom overlays, including the top of the load beam collar's flange. This results in the whole outer perimeter of the box being hidden beneath the overlay.

Information is provided on this page that can inspire anyone to customize covers to suit their own needs.

Custom Inlaid Covers

The cover provides a unique customization opportunity; it allows a wide variety of materials to be applied to its upper surface. These can be anything from carbon fiber to wood veneers. This section will perform a simple walkthrough of making a bamboo veneer cover.

Finished Inlay

Finished Inlay

Step-by-step Guide

Inlay Start showing Parts

Inlay Start showing Parts

Start with the standard ABS plastic cover that comes with every box. These covers can be ordered loose so they can be modified. We recommend using GREY covers as this allows them to blend in better with the box's color. It is also recommended that HEX covers to be used for the reasons explained below.

A piece of the material that will form the inlay on the cover will also be needed. Here we show a bit of bamboo veneer for this purpose.

Step 1

STEP 1: Sanded Down Cover

STEP 1: Sanded Down Cover

The cover is sanded down by the thickness of the veneer so that, once installed, the cover is still flush with the top edge of the flange. If a HEX cover is used, it is easy to gauge the depth and sand down until the hex scoring disappears.

This depth is typical for a lot of different veneers. Hex covers are also much easier to sand, and it is faster to remove the plastic because of the scoring

Step 2

STEP 2: Cover glued to veneer

STEP 2: Cover glued to veneer

Place a piece of veneer face down on some tempered glass. Apply glue (we use SuperGlue) to the upper surface of the cover and place it top down onto the back of the veneer.

Place a piece of wood on top of the cover and apply a couple of clamps, clamping the whole assembly to the glass. This ensures that the assembly will be flat. Wipe off any excess glue.

Step 3

STEP 3: Trim excess veneer

STEP 3: Trim excess veneer

Once the glue has set, trim away any excess veneer from the outside of the cover. Also, cut out the veneer from the interior of the cover to remove the extra material. We use scissors on the outside and a box cutter on the inside.

Step 4 & 5

STEP 4: Sand veneer flush with edges

STEP 4: Sand veneer flush with edges

STEP 5: Finished cover

STEP 5: Finished cover

Once the glue has set, trim away any excess veneer from the outside of the cover. To remove the extra material, cut out the veneer from the interior of the cover. We use scissors on the outside and a box cutter on the inside. Then, using a sanding block, true the veneer to the outside of the cover.

For the inner edge, a Dremel tool with a sanding drum to sand the veneer flush to the cover's internal profile. Finally, clean up any burring on the veneer's edges with 220-grit sandpaper.

NOTE: The cover has an 8Âş slope to the outer and inner edges. Be sure to sand at this angle to get the best fit.

Finished

Completed inlaid cover glued into the box

Completed inlaid cover glued into the box

Once the cover is finished, it should be glued into the box with SuperGlue; this eliminates any problems if the cover is not flat in the collar. It only takes a small amount of time to glue a cover into the box, four little drops of glue. A small spring clamp on each end, and each side will hold it in place. Once installed, the resin will lock the cover permanently in place.

Bamboo veneer tends to splinter at the edges when being sanded. To make it easier to manage, apply some catalyzed sanding resin to the glass before placing the bamboo. This will give the bamboo a smooth finish and help prevent splintering. Also, sand the upper surface before installing it to remove the wax from the resin and improve the bond.

This process can be followed for different materials; just let your imagination run with it!

Custom Overlaid Covers

The cover provides a unique customization opportunity. Its upper surface can be covered with various materials, from carbon fiber to wood veneers. This section will perform a simple walkthrough of making a bamboo veneer overlay cover.

Finished overlay box

Finished overlay box

We have previously shown how the cover's upper surface can be customized. Another aspect of the system's design is that thin overlays can be applied over the top of the cover and the upper edge of the box flange.

In this section, we will perform a simple walkthrough of making a veneer overlay.

Step-by-step Guide

Start overlay with a hex cover

Start overlay with a hex cover

Start with the standard ABS plastic cover that comes with every box. These covers can be ordered loose so they can be modified. We also recommend using GREY covers as this allows them to blend in better with the box.

Step 1

Sand the top of the cover

Sand the top of the cover

The upper surface of the cover is sanded lightly to remove the shiny surface. After sanding, clean off any burrs on the edges, particularly along the outside edge.

Step 2

Glue the sanded cover to the back of the veneer

Glue the sanded cover to the back of the veneer

Place a piece of veneer face down on some tempered glass. Make sure the veneer is large enough to allow the outside to cover the perimeter of the box's flange fully. Apply glue (we use SuperGlue) to the upper surface of the cover and place it top down onto the back of the veneer.

Place a piece of wood on top of the cover and apply a couple of clamps, clamping the whole assembly to the glass. Wipe off any excess glue, paying particular attention to the outside perimeter as we don't want any glue on this part of the veneer.

Step 3

Sand the interior of the cover flush

Sand the interior of the cover flush

Once the glue has set, remove the clamps and trim the excess veneer on the inside with a box cutter. Use a Dremel tool with a 3/8” sanding drum to sand the veneer flush to the inner shape of the cover. Clean up any burring on the inner edges of the veneer with a piece of 220-grit sandpaper. Leave any excess veneer on the outside, as this will be trimmed off after the next step.

NOTE: The cover has an 8Âş slope to the outer and inner edges; sand at this angle to get the best fit in the box.

Step 4

Glue the cover to the box

Glue the cover to the box

Once the cover is finished, it should be glued into the box with SuperGlue; this eliminates any problems if the cover is not flat in the collar. It only takes a small amount of glue to glue a cover into the box: four little drops of glue in the ends and sides of the collar. Plus, run a bead of glue around the entire outside perimeter of the cover. This will ensure the veneer is glued to the collar's flange.

Step 5

Clamp the glued cover to the box

Clamp the glued cover to the box

Small spring clamps should be applied around the perimeter of the flange to clamp the cover and veneer to the box. Leave clamped for a couple of hours.

Finished

Finished overlay cover and box

Finished overlay cover and box

Once the glue has cured, remove the clamps and cut off any excess veneer on the outside with scissors. Next, use a sanding block to sand the veneer flush with the outside surface of the flange.

NOTE: There is a slight angle to this outside the flange; try to match this angle when sanding. Try not to sand off too much of the plastic. The goal is to flush the veneer to the outside surface of the box.

WARNING: When installing an overlaid box, the depth of the router bit must be adjusted to accommodate the extra thickness of the overlaid material. As before, the goal is to have the box's finished upper surface slightly below the blank's upper surface.

Gluing the Cover into a Box

Glue dot placement on box

Glue dot placement on box

This drawing shows the glue dots' placement on the flange's inner surface. The best glue to glue the cover to the box is some form of cyanoacrylate glue (commonly referred to as SuperGlue®). We use DAP RAPIDFUSE® for all of our cover gluing as it sticks well to polycarbonates

Example of a custom overlay using abalone

Example of a custom overlay using abalone

GEARBOX - An advanced removable surfboard fin system.

GEARBOX Surf has locations in Australia and Hawai'i (USA). Contact information is provided here, but the preferred method is to use the contact form on this site.

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INFO
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GEARBOX Surf Hawai'i
Hanalei, Kauai

+1 808 639 5303

SANDED Australia
NSW, Australia

+61 243 399 580

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Finished Inlay
Inlay Start showing Parts
STEP 1: Sanded Down Cover
STEP 2: Cover glued to veneer
STEP 3: Trim excess veneer
STEP 4: Sand veneer flush with edges
STEP 5: Finished cover
Completed inlaid cover glued into the box
Finished overlay box
Start overlay with a hex cover
Sand the top of the cover
Glue the sanded cover to the back of the veneer
Sand the interior of the cover flush
Glue the cover to the box
Clamp the glued cover to the box
Finished overlay cover and box
Glue dot placement on box
Example of a custom overlay using abalone