100% Handmade
Sky Ski Hydrofoils are 100% handmade in the great US of A by a small handful of dedicated, good ol’ boys out of Redding California!! We are proud to say that we are the last waterski company that still manufactures 100% of our Hydrofoils right here in the Land of the Free and the Home of the Brave.
How Do We Do It?
Well, we start out with the best designs created in Solidworks and Mastercam. This allows us to “stress-test” the parts while still in the design phase, showing us where the weak link is, where it needs to be the strongest, where it needs to flex, and where material can be eliminated to make the part lighter.
Best Raw Materials
Once the part is designed we order the best raw materials available. For our seat towers and foil assemblies this would be raw, aircraft quality 6061 T6 plate aluminum. Billet aluminum & cast aluminum are completely different materials, and anyone that might try to tell ya differently might just have an ocean front property to sell ya too.
All-American Made
Now that we have designs that are ready to roll, and material in the house its time to put our all-American made Haas CNC Mills & Lathes to work. With aluminum chips a’flyin, coolant a’sprayin, tools spinnin and tables a’ slidin, in goes raw aluminum, out come actual parts, ready to be assembled, sanded, polished, grained, tumbled or whatever the next step may be.
A Whole 'Nother Story
SkySki Hydrofoil boards are a whole ‘nother story, although the process is quite similar as with our aluminum components. We start out with only the best raw materials at every single level. First we mix our foam and shoot our very own foam cores. While they are curing (it takes a day or 2 or so) we get to cutting fiberglass and carbon fiber for the lay-up schedules.
Good 'Ol Boys!
When the boards come out of the press they get flashed, routed, filed, drilled for seat tower & bindings, and finally inspected. If everything checks out, they get paired with the appropriate seat tower and foil assembly. The cool thing about this whole process is that it all happens under one roof. Our roof, the Sky Ski roof. Not bad for a handful of good ol’ boys, eh?