DIY Hydrofoil Wing Build — Carbon Fiber & Wood Core with NACA foil profile

In this video, I walk through how I built a front wing from design to shaping to carbon fiber/epoxy lamination, using a simple wooden core and a vacuum bag setup. No CNC machine required!
I built a simple copy router to follow a NACA foil shape. This same process could be used for any type of hydrofoil wind for windfoiling, winging, kiting, or surfing!

Full walkthrough: design, shaping, carbon lamination, finishing
No CNC machine needed—just creative woodworking and composite work
Great for windsurf foiling, wing foiling, kiteboarding foils, and surf foilboards

Materials & Keywords:
DIY hydrofoil, wood core, carbon fiber lamination, vacuum bag, windfoiling, wing foiling, foil surfing, kite foil, hydrofoil wing build

In the video:
ChatGPT-assisted NACA foil design & full-scale drawing
Homemade Dremel copy router shaping
Carbon trailing edge and vacuum-bag lamination
Cut-lap method, peel-ply, breather, hot coat, and wet sanding
Spray-paint finish with smooth results

Chapters:
00:00 – Intro
00:23 – Design & NACA Profile (ChatGPT integration)
01:30 – Shaping with DIY Copy Router
05:01 – Fuselage Mount Prep & Trailing Edge Build
05:53 – Carbon Lamination (cut-lap method)
08:31 – Vacuum-Bag
08:53 – Peel-Ply Removal & Sanding
13:02 – Hot Coat, Wet Sanding, Fill & Finish
16:23 – Final Surf-Ready Safety Check & Outro

Other DIY foil build videos:
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