Custom Skis and Monoski
As a lifelong skier, I’ve always been interested in ski construction and technology. Despite having a relatively simple composite construction, small tweaks in material or shape can transform the feel of a ski and vastly change the experience. In 2021 I decided to design and build a pair of my own skis.
I built a parametric CAD model that allowed me to experiment with many design variables. The website Soothski was a great resource for obtaining precise dimensions and flex for existing skis, helping me narrow in on the performance I wanted. Once I settled on a design suitable for my skiing style, I was able to build a mold and prep all the necessary materials.
The skis have industry-standard UHMW Polyethylene bases and steel edges. I opted for a poplar wood core and 2 layers of triaxial fiberglass to give the skis their strength. The layup process and finishing work went well for the most part but there was definitely room for improvement. The fit and finish is lacking compared to commercial products, and while skiing with them I found the flex pattern to be too soft for my skiing style. I attribute this mostly to using a solid poplar core instead of a laminated core.
A year later I revisited the project, coming up with a new design for a custom monoski. The materials and construction were similar, but the experience I had led to significant improvement. An upgraded mold and better material preparation resulted in more evenly distributed clamping force, less excess resin, and a more refined final product. The build process was smoother and I have used the monoski for 20+ days so far with no issues.
It was really fun digging deeper into a hobby I enjoy so much and gaining an understanding of how the technology has improved over the years. Most days I’m still on a pair of Black Diamond or WNDR skis, but it’s special to bring out the monoski every once in a while.
Photo Gallery
