INTRODUCTION TO THE 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. A design 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 for 2023 is a move to WHITE color boxes with an enhanced material. This new material features an increase in fiber content for additional strength.
Enjoy exploring!
OVERVIEW
DETAILS ON THE MAIN COMPONENTS OF THE 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.
COVERS
One of the unique features of the GEARBOX system is the load beam cover. It exists to allow for better adhesion and customization.
STD ROUTING SYSTEM
The standard routing system performs a typical install, a two-part rout in either polyurethane or high-density EPS foam.
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.
OVERVIEW
While the GEARBOX system is simple, much thought and care went into its development and design.
An unprecedented amount of innovation is occurring with fins and fin systems, ranging from simple to complex, toolless fin attachment to a wide range of other options.
Our choice was to go back to basics with a light and robust system while simultaneously being simple to install and easy to use. A design optimized for under-the-glass installation. The goal was to deliver a simple and familiar 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 creates 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 an optimal bonding area. In addition, the outer flange of the load beam encapsulates the cover. More important is the unique aesthetic created once installed on a board. Makes the appearance of a pin line around the outer perimeter of the box.
The high-density expanded ABS utilized in the cover, being stiff, imparts additional rigidity to the collar!
The design of the collar 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. It facilitates different appearances for the installation of the box.
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 in 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 process 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. The system also supports a single routing option (1ROUT) if one of our HD foam support blocks is utilized. These blocks are sold separately and have been machined for a precise fit in the routed cavity and to the box.
DESIGN PHILOSOPHY
GEARBOX was designed against a small set of essential design principles. To better help understand the design choices made for the system, more details on some of the design criteria are discussed here. It is also important to realize that the system is not static; we are constantly making tweaks to improve the product!
STRENGTH
This has been our primary focus for the many years we have spent developing the system. We were adamant that we wanted the strongest and lightest box we could design. So many different aspects of a design can impact strength, from material selection to shape. Our design addresses all characteristics that can influence this critical element.
We derived strength from two different aspects of our design. First, our patented load beam collar handles the loads, dissipating them throughout the structure. Also, the depth of the beam allows for increased shear strength around the perimeter. Installation strength is critical to spreading loads, on the box, throughout the entire structure. Our installation technique and the load beam design enhance this strength.
It is also worth pointing out that the shape of our box also plays a significant role in strength. The large footprint is better able to handle rolling loads while at the same time providing a unique appearance!
APPEARANCE
Not something has been given much consideration when looking at current fin systems. They range from bland chunks of plastic to random shapes that don't always complement the surfboard. Due to our load beam's unique design, we have created an aesthetic not seen in other fin systems. With our method, the box vanishes into the board once installed. The cover in the load beam facilitates this by completely hiding the underlying structure. All that remains visible is a thin outline of plastic around the perimeter, plus the dam surrounding the slot and screws. It doesn't get more minimal than this!
We decided that the load beam should support various cover material types. Therefore, we select cover materials with good bonding strength from multiple choices. Additionally, we have a wide range of color covers that make it simple to enhance the system's appearance when installed on a board!
WEIGHT
In modern surfboard design, weight is a critical component. This has always been a high priority for our design. We wanted the lightest possible box that met our strength requirements.
There are many ways of reducing weight, but doing so without compromising strength can be a delicate balancing act. The design and shape of our load beam have allowed us to push the weight reductions to the limit! But we chose not to sacrifice strength for weight!
SIMPLICITY
We wanted to keep the system as simple as possible! It needed to be easy to understand how it worked and how to work with it. We stuck with many tried and true techniques for creating a removable fin system to achieve this.
Focus remained on the customer. The system needed to be approachable and familiar to all surfers! We achieved this by limiting the options and sticking with grub screws for locking the fin in place!
EASY INSTALLATION
Here we once again tried to rely on what board builders are already familiar with in their factories. The system had to be an under-the-glass install, eliminating an extra step compared to a post-install and saving time and expense for the board builder.
These days most use either a two-step process or a single rout. We elected to use a two-step routing process as it better fits our load beam's unique aspects. Ours differs because we have a much deeper load beam.
To simplify the process, we designed an entire routing system that minimized the number of steps. Different construction techniques sometimes need a different installation process. We designed our system to enable these alternate installation options.
COMPATIBILITY
The system is compatible with all available dual tab fins, providing the widest array of fin choices.
GEARBOX Anatomy
BOXES
The GEARBOX fin system consists of six (6) different boxes. Five (5) side boxes featuring different cant angles, a dedicated center box, and a load beam collar cover. They were designed for placement underneath the glass during the lamination process or as a post-lam install.
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. Features a broad mid-section providing 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, the cover in a balsa wood board could be balsa, so the box blends in with the surrounding wood. The cover enables the application of various overlays, for example, carbon fiber, fiberglass, etc. They are facilitating customization of the box appearance and allowing the boxes to blend in with the rest of the surfboard!
Side box covers feature a recessed cant angle number centered at the outboard edge. This number indicates the cant angle of the associated box. Supported cant angles - 0º, 2º, 4º, 6º, and 8º. The cant angle is also marked in the slot and on the bottom outside of the box. We are making it easier to identify the cant angle.
The outer flange of the collar provides an aesthetic detail by forming a thin pin line around the cover's perimeter.
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.
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 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.
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.
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.
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. Connecting the sides in this manner means the slot is 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.
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.
The GEARBOX fin base is a full-length base that 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. I am 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. Sandwiches the web of the load beam, locking it in place!
Hex covers are now the standard cover for the GEARBOX system. A hexagonal scoring pattern is engraved into the upper surface of the cover. In addition, to the usual excellent bonding properties of the cover material, the scoring adds an improved mechanical bond!
The load beam cover provides the bottom laminate with the greatest bonding surface. Thereby allowing for a more robust installation. The cover extends down through the trussing of the load beam, providing a better bond to the underlying foam shelf. Sandwiches the web of the load beam, 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! 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 balsa 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.
Installation strength is further improved through the extensive trussing in the load beam web. The cover extends through these truss openings, creating a bond between the cover and the surfboard foam.
The bonding properties of the material drive cover material selection to surfboard resin systems. Examples include high-density foams, carbon fiber, wood veneer, fiberglass, or other structural materials. Provides greater creative flexibility with the box installation.
Optional color covers are available in seven colors - 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!
For 2023 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. Not only does this cover facilitate better bonding with the laminating system, but it also 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, two distinct types of customization can be performed on the covers.
Hex Covers
Hex covers are used for most of the customization options. There are two different types of customization - inlay and overlay.
The inlay process involves sanding down the cover by the thickness of the inlay material that will be added to the top surface. Typically, the inlay materials are selected based on the resin absorption of bonding characteristics. The most common materials are wood veneers, which are relatively thin and easy to apply to the surface while providing excellent resin absorption.
Customization is most commonly built on top of an existing cover to control the fit into the collar better. But it is possible to replace the cover with a different material completely.
For the overlay process, a material is added to the top of the cover that extends over the flange lip and completely hides the box's edges. Finally, we provide a simple guide to cover customization customization.
Hex Covers - Color Fill
Hex covers can also be customized by filling the grooves in the covers with different color resin, allowing the hex pattern to be accentuated. This is easily performed with a syringe, then once the resin has cured, the top cover surface is sanded down. A guide providing instructions on customization will be found customization.
STANDARD 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.
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 as a set or individually, 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.
The base jig is the foundation of the routing system. Ensures correct placement of the routing system. A soft rubber pad on the bottom prevents damage and minimizes the movement of the jig.
Features several markings on the upper surface to place on a board correctly. It is made from glass-filled polycarbonate, making them inexpensive and durable.
The base jig is the primary jig, locates the system on the surfboard, and isn't removed until the routing process is complete. 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.
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.
The bottom jig is placed within the inner cutout of the base jig to rout the cavity for the bottom of the box. No positioning is required; drop it into the base jig and then rout the cavity. For this operation, the router bit is set to the deepest depth.
Like the base jig, this jig has a rail side indicator to help orient the jig. It is made from glass-filled polycarbonate.
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.
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.
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!
The final piece of the install 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.
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.
The routing system also has a printed install guide detailing the entire process. The STANDARD Install Guide covers the basic installation process for normal boards. A separate guide is provided for low-density EPS installation in the form of the 1ROUT Install Guide. A lot of information on correctly installing the system is provided, with variations for different construction techniques.
The information available in the various install guides can also be found on this site, along with much other information about the installation process.
More details here - INSTALL DETAILS
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.
The routing of the single cavity is handled by the base router jig from the standard routing system, the other two jigs from the system are not utilized.
It also includes a router bit, hex key, and install guide.
The base jig is the foundation of the routing system. Ensures correct placement of the routing system. A soft rubber pad on the bottom prevents damage and minimizes jig movement.
Features several markings on the upper surface to assist with placement on a board correctly. It is made from glass-filled polycarbonate, making them 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, locates the system on the surfboard, and isn't removed until the routing process is complete.
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 shapers 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 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.
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!
The final piece of the install 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.
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.
The routing system also has a printed install guide detailing the entire process. The STANDARD Install Guide covers the basic installation process for normal boards. A separate guide is provided for low-density EPS installation in the form of the 1ROUT Install Guide. A lot of information on correctly installing the system is provided, with variations for different construction techniques.
The information available in the various install guides can also be found on this site, along with much other information about the installation process.
More details here - INSTALL DETAILS
GEARBOX - An advanced removable surfboard fin system.