GEARBOX System

GEARBOX is a unique fin box design with some features not found in other fin systems.

GEARBOX is a light and strong system that is simultaneously simple to install and easy to use. Its design is optimized for under-the-glass installation. The goal was to deliver a system that was both simple and easy to install.

GEARBOX is as light as possible without compromising its strength. The unique patented design delivers unprecedented strength for an under-the-glass system.

This site has a lot of information about various aspects of the system.

New in 2023 was a move to WHITE color boxes with an enhanced material. This new material features an increase in fiber content for additional strength.

Enjoy exploring!

The complete GEARBOX fin system

Overview

Details on the Main System Components

A high-level overview of the complete system.

Presented here is a high level overview of the main components of the system. Navigate from here for an in depth overview and greater detail on each of these components.

There is a lot of information about the system, but it can be explored progressively, as needed.

Boxes

There are a lot of unique features to the system, starting with the design of the boxes. Explore all of the details in this section.

Details

Covers

One of the unique features of the GEARBOX system is the load beam cover, which allows for better adhesion and customization.

Details

STD Routing SyStem

The standard routing system performs a typical install, a two-part rout in either polyurethane or high-density EPS foam.

Details

1ROUT Routing System

The 1ROUT routing system performs installs in low-density EPS foam, where an HD foam backing block provides additional support to the box.

Details

System

While the GEARBOX system is simple, much thought and care went into its development and design.

Anatomy of a GEARBOX

Anatomy of a GEARBOX box

Fins and fin systems are experiencing unprecedented innovation. They range from simple to complex, from toolless fin attachment to many other options.

We chose to go back to basics with a light and robust system that was simultaneously simple to install and easy to use. This design was optimized for under-the-glass installation. The goal was to deliver a familiar and straightforward system for builders to install and surfers to use.

GEARBOX is as light as possible without compromising its strength. The unique patented design delivers unprecedented strength for an under-the-glass system.

Current under-the-glass systems rely on the bond between the laminating resin and a plastic flange surrounding the box. This is less than optimal! GEARBOX turns the flange concept on its head by placing the web of the flange lower down on the box, creating a load-beam collar. This collar makes a flange shaped to form a cup on its upper surface, and a cover is placed within this cup.

We select a cover material that provides optimal bonding to the resin system. The entire exposed upper surface of the cover allows the bottom laminate of the surfboard to have an optimal bonding area. In addition, the outer flange of the load beam encapsulates the cover. More important is the unique aesthetic created once the cover is installed on a board. It establishes a line around the outer perimeter of the box.

The high-density expanded ABS utilized in the cover is stiff and imparts additional rigidity to the collar!

The collar's design does not restrict the cover material. Anything providing a good bonding surface is acceptable. For example, in a balsa wood board, the cover could be balsa so that the box blends in with the surrounding wood. The cover's design supports the application of inlays or overlays to its upper surface, facilitating different appearances for the box's installation.

While many stylistic uses exist for the cover, the primary criterion is good bonding with the resin system. Covers are also available in various primary colors to provide further customization options!

The cover also has a recessed cant angle indicator at the outboard edge. It is used to quickly check the cant angle of the box once installed on a board, and when there is a fin in the box.

GEARBOX employs a familiar screw placement on the box's inner side, generating a locking force on the fin base. The fin bases have recesses onto which the screws land to help force the base into the slot. Center boxes have opposing screws. A bridge in the center of the slot ties the two sides together to resist the lateral forces on the box.

To assist in fine-tuning a board, the slot features 5mm (3/16") of movement forward and backward. Not only does this help when installing a fin, but it also facilitates control over the performance of the fins.

The box's slot is compatible with dual tab fins and our full-length base.

The two-step installation creates a cavity with a shelf onto which the load beam collar rests, providing better bonding to the surfboard foam. The complete routing system makes the installation process simple. If one of our high-density foam blocks is utilized, the system supports a single routing option (1ROUT). These blocks are sold separately and have been machined for a precise fit in the routed cavity and to the box.

Boxes

The GEARBOX fin system consists of four (4) boxes: three (3) side boxes featuring different cant angles, a dedicated center box, and a load beam collar cover. They were designed to be placed underneath the glass during the lamination process or as a post-lam installation.

Side and Center Boxes

A unique, patented load beam collar with a cover turns the entire top surface of the cover into a bonding surface. Truss openings in the load beam collar lighten the weight without sacrificing strength. In addition, the beam's outline shape improves the system's roll strength once installed. It features a broad mid-section that provides the most significant possible footprint without impeding close-to-rail installation.

The collar's design does not restrict the cover material to any one material. Anything providing a good bonding surface is acceptable. For example, a balsa wood board cover could be made of balsa, so the box blends in with the surrounding wood. The cover enables the application of various overlays, such as carbon fiber, fiberglass, etc. These overlays facilitate customization of the box appearance and allow the boxes to blend in with the rest of the surfboard!

Three cant angles are supported: 4º, 6º, and 8º. The cant angle is marked in the slot and on the bottom outside of the box.

GEARBOX Box Dimensions

The fin slot provides adjustment of 5mm (3/16") forward and backward. Allows fin placement to be fine-tuned and designed to be compatible with all dual-tab fins on the market. Each box ships with a card containing three pieces of die-cut masking tape. These are used to cover the slot and screws during installation. Side boxes ship on trays containing ten boxes, die-cut masking tape, and two hex keys. Center boxes ship in packs containing five boxes.

Box Collar Details

The load beam collar is a unique, patented characteristic of the GEARBOX design. The cup-shaped beam's location is below the box's upper surface. Therefore, a high-density material placed within the load beam increases the bonding area for the bottom laminate. This is called a cover.

The selection of cover material is based on good resin adhesion characteristics. Installation bonds the entire cover into the collar. It turns the load beam collar into a solid structural entity that is efficient at load dissipation. The design of the collar results in a cover with the greatest amount of exposed surface area possible. It allows for a superior bond with the bottom laminate of the board.

Dam Details

A dam is a requirement for an under-the-glass system. It provides a ramp over which the bottom laminate can be draped, exposing the dam when sanding the board. It also allows the grub screws to be protected during the laminating process.

The die-cut masking tape that fits the top of the dam to cover the slot and screws during lamination is provided. The dam has high enough clearance above the bottom lamination to allow it to be sanded down to expose the slot and screws.

Slot Details

The fin slot provides housing for the fin base and is designed to provide a snug fit. The GEARBOX slot also provides a 3/16" (5mm) adjustment for the fin, allowing the fin position to be tweaked!

The slot supports both GEARBOX and DUAL TAB bases.

Slot Bridge Details

GEARBOX features a bridge at the center of the fin slot on the bottom. This bridge ties the two sides of the slot together for additional strength, making the slot less likely to spread apart under the loads applied to the base of the fin.

GEARBOX fin bases have a corresponding semi-circular notched cutout to fit over the bridge. Dual tab bases fit either side of the bridge.

Grub Screw Details

GEARBOX utilizes two grub screws to lock the fin into the slot. The screws are tightened into a notch in the fin base that pushes the fin down, locking it into the slot.

Two screws are placed on the stringer side of the box for side boxes. While the center box, the screws are on opposing sides of the box.

Fin Base

The full-length GEARBOX fin base provides the strongest support in the slot. This minimizes the amount of flex in the base of the fin, allowing it to flex as designed.

The base features notches on the side, onto which the grub screws land allowing for a compression fit into the box. These notches are designed to support adjusting the fin position within the slot. The notch also minimizes the risk of the fin falling out of the box should the screws loosen.

Covers

The cover provides the greatest possible bonding surface for the bottom laminate. Allowing for a stronger installation. The cover extends down through the trussing of the load beam, providing a better bond to the underlying foam shelf. Sandwiching the web of the load beam, locking it in place!

Side and Center Covers

Hex covers are now the standard cover for the GEARBOX system. The upper surface features a hexagonal scoring pattern. In addition to the cover material's usual excellent bonding properties, the scoring improves the mechanical bond!

The load beam cover provides the bottom laminate with the greatest bonding surface, allowing for a more robust installation. The cover extends down through the load beam's trussing, providing a better bond to the underlying foam shelf and sandwiching the load beam's web, locking it in place!

Because the cover is separate from the box, its material can be optimized to provide the best bonding characteristics. All covers come pre-installed in a box with a sanded upper surface, but loose covers can be purchased for customization purposes.

Besides the structural role that the cover plays within the load beam, it also has an aesthetic aspect. The large surface area can be covered in different overlays to enhance the appearance of the installed box. In addition, customization options are available for the cover. For example, using balsa veneer on a wood board would complement the appearance. This decorative covering is applied to the upper surface of the cover and can provide a wide range of other design options. These coverings range from carbon fiber to wood veneers or printed fabrics.

The extensive trussing throughout the load beam web further improves installation strength. The cover extends through these truss openings, bonding it with the surfboard foam.

The bonding properties of the material drive the selection of cover material for surfboard resin systems. Examples include high-density foams, carbon fiber, wood veneer, fiberglass, or other structural materials. These materials provide greater creative flexibility with box installation.

Color Options

Seven optional colors available: black, gray, yellow, mango, red, blue, green, and purple. All these colors are also available for the center covers.

All color covers are HEX covers only! All of these colors are made from expanded ABS.

NOTE: colors shown might not exactly match the finished product!

The covers no longer feature the cant angle indicator, as managing inventory for the different angles was becoming impossible. Now, all covers are blank and, therefore, interchangeable.

One of the unique aspects of the GEARBOX system is the use of a cover in the load beam collar. This cover facilitates better bonding with the laminating system and provides a unique customization opportunity.

Covers can be optimized by overlaying the top surface with materials ranging from wood veneers to exotic composite materials!

Depending on which cover is used as the base, the covers can be customized in three ways: overlay, inlay, or color inlay. The site's Customization page provides more details.

STD Routing System

The primary installation method is a two-step process. First, it creates a cavity with a shelf onto which the box’s load beam collar rests. The lower part of the cavity houses the bottom of the box. To ease the routing of these cavities, the routing system includes jigs that simplify the routing process. These jigs allow routing without adjusting the router bit's depth.

Annotated Standard Routing System

The system consists of three jigs: base, bottom, and top. The base jig is the primary positioning jig that locates the other jigs.

The bottom jig routs the center cavity for the bottom of the box. It nests within the base jig when in use. Finally, the top jig routs the shelf onto which the box rests. This jig sits on top of the base jig and has overhanging ends that position it on it. The thickness of this jig sets the correct depth of the router bit.

In addition to the complete routing system, the jigs can be purchased individually or as a set, making it simple to replace any part of the system when needed.

All jigs are made from glass-filled polycarbonate, which is strong, durable, and inexpensive.

Base Router Jig

The base jig is the foundation of the routing system and ensures the correct placement of the system. A soft rubber pad on the bottom prevents damage and minimizes the jig's movement..

The upper surface has markings that can be used to place it on a board correctly. It is made from glass-filled polycarbonate, which makes it inexpensive and durable.

The base jig is the primary jig. It locates the system on the surfboard and isn't removed until the routing process is complete. The jigs are designed to make this process as simple as possible. Small windows extend through each end of the jig, making it easier to position the jig on the shaper's mark.

Annotated Base Router Jig

They are used in conjunction with a pair of centerlines extending the length of the jig and down inside the central cutout in the jig. There are two centerlines. One that represents the actual center of the box and runs down the center of the jig. Used when installing a center box. The side box centerline positions the side boxes; this centerline represents the inner face of the fin slot.

Marks on the jig help alignment when installing side boxes. An arrow and the word "Rail" indicate the jig's positioning relative to the surfboard's rail. Two shapers mark windows so that they work for both sides of the board. The back window on the jig is always used to position the jig on the shaper's mark. The base jig has a soft rubber pad on the bottom to protect the surfboard and prevent the jig from moving.

The bottom of the base jig is also shaped to make it easier to place in deep double concaves and for easier handling, and accomplished with a 45º chamfer around the bottom edge of the jig, made from glass-filled polycarbonate.

Bottom Router Jig

The bottom jig is placed within the inner cutout of the base jig to rout the cavity for the box's bottom. No positioning is required; drop it into the base jig and then rout the cavity. The router bit is set to the deepest depth for this operation.

Like the base jig, this jig has a rail-side indicator to help orient the jig. It is made from glass-filled polycarbonate.

Top Router Jig

This jig is used to rout the shelf onto which the box rests. After routing the bottom cavity, the bottom jig is removed, and the top jig is placed on top of the base jig. The jig is positioned on top of the base jig with locators that lock the jig in place.

The jig automatically adjusts the router bit depth. Like the base jig, this jig has a rail-side indicator to help position the jig. It is made from glass-filled polycarbonate.

Router Bit with Bearing

The system utilizes a router bit with an upper bearing. This bearing runs against the inner surface of the routing jigs, generating the correct outline.

The router bit has a 6mm (1/4") shank. 9.5mm (3/8") cutting diameter. 19mm (3/4") cutting depth. Utilizes a 13mm (1/2") diameter bearing.

Hex Key

A hex key is provided with the routing system. This key is used to adjust the grub screws before installation of the boxes. In addition, it features a full-size Allen wrench housed within the plastic, which is very effective.

It is also used when installing fins in the system.

WARNING: do not over-tighten screws as this can lead to stripping!

Router Bit Depth Gauge

The final piece of the installation system is a depth gauge that is used to set the depth of the router bit. It is used as shown in the illustration below. There are two separate depth settings on the gauge: STANDARD (circular notch on the side) for a typical install and CONCAVE (triangular notch on the side) for installations in double concaves; this depth is 1/32" deeper than the standard install.

Router Bit Setup

The side with a notch is always up to get one of the two depths - CIRCULAR = STANDARD and TRIANGULAR = CONCAVE. Then, the flat edge is placed on the router base, as shown, and the depth is adjusted till the cutters touch the gauge.

1ROUT Routing System

The 1ROUT or EPS installation method is a single rout process. It creates a single cavity into which an HD foam block is installed. The box then fits into the foam block, providing a stable support system.

Annotated 1ROUT Routing System

The routing of the single cavity is handled by the base router jig from the standard routing system; the other two jigs are not utilized.

It also includes a router bit, hex key, and installation guide.

Base Router Jig

The base jig is the foundation of the routing system. It ensures the correct placement of the routing system. A soft rubber pad on the bottom prevents damage and minimizes jig movement.

It features several markings on the upper surface to assist with placement on a board correctly. It is made from glass-filled polycarbonate, making it inexpensive and durable.

This is the only jig needed for 1ROUT/EPS installs, as this routing system involves a single rout.

The base jig is the primary jig. It locates the system on the surfboard and isn't removed until the routing process is complete.

Annotated Base Router Jig

They are designed to make locating the system on the surfboard as simple as possible. Small windows extend through each end of the jig, making it easier to position the jig on the shaper's mark, used in conjunction with a pair of centerlines extending the length of the jig and down inside the central cutout in the jig. There are two centerlines. One that represents the actual center of the box and runs down the center of the jig. Used when installing a center box. The side box centerline positions the side boxes. This centerline represents the inner face of the fin slot.

The bottom of the base jig is also shaped to facilitate placement in deep double concaves and handling. This is accomplished with a 45º chamfer around the bottom edge of the jig, which is made from glass-filled polycarbonate.

Router Bit with Bearing

The system utilizes a router bit with an upper bearing. This bearing runs against the inner surface of the routing jigs, generating the correct outline.

The router bit has a 6mm (1/4") shank. 9.5mm (3/8") cutting diameter. 19mm (3/4") cutting depth. Utilizes a 13mm (1/2") diameter bearing.

Hex Key

It is also used when installing fins in the system.

WARNING: do not over-tighten screws as this can lead to stripping!

Router Bit Depth Gauge

Router Bit Depth Setup

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.

SYSTEM

INFO

BUSINESS

GEARBOX Surf Hawai'i
Hanalei, Kauai

+1 808 639 5303

SANDED Australia
NSW, Australia

+61 243 399 580

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2. How We Use Your Information

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8. Contact Us

Mair Designs LLC

GEARBOX System

Overview

Details on the Main System Components

System

Anatomy of a GEARBOX

Boxes

Covers

STD Routing System

1ROUT Routing System

SYSTEM

INFO

BUSINESS

Privacy Policy

1. Information We Collect

2. How We Use Your Information

3. Sharing Your Information

4. Cookies

5. Your Rights

6. Third-Party Links

7. Changes to This Policy

8. Contact Us

Mair Designs LLC

Privacy Consent

GEARBOX System

Overview

Details on the Main System Components

System

Anatomy of a GEARBOX

Boxes

Covers

STD Routing System

1ROUT Routing System

SYSTEM

INFO

BUSINESS