Rose Topsheet Skis – Finished Build and Lessons Learned
After months of planning and work, I finally completed my rose inlay twin-tip skis and I’m pretty happy with the result.
These skis feature a laser-cut floral veneer topsheet inlay, assembled by hand using my extended 8-foot laser rig. The graphics are cool! That said, there were some valuable lessons along the way I’ll be carrying into my next builds.
First of all, here they are:
What Went Well
- The laser inlay design translated well onto the full-length ski, especially from a distance.
- Core alignment and construction were solid — I’m feeling much more confident shaping and pressing these builds with the techniques I’ve developed.
- The twin-tip shape and flex came out just as planned, perfect for park or all-mountain freestyle skiing.
Key Lessons From This Build
1. Flatten the Veneer More Thoroughly
Some of the leaf and flower inlay pieces didn’t align perfectly — mostly due to slight warping in the paper-backed veneer I used. I thought weighting it down overnight would be enough, but I now realize I need to fully flatten the veneer before laser cutting or assembling. I also plan to stick to raw veneer when possible, or use veneer softener + press flattener before cutting.
2. Sidewall Router Beveling Is Tricky
While shaping the final edge bevels, I nicked the sidewall with the router. It’s minor, but it shows how important patience with the router is. Despite the nick, I’m getting better at doing these bevels freehand but a jig is still on my mind to improve consistency.
3. Epoxy Topsheet Finishing Was… a Nightmare
Here’s where things went sideways: I experimented with a poured epoxy finish over the topsheet instead of using oil + wax or 2-part poly.
The idea was to get a glossy, glass-like finish, but the epoxy:
- Pooled unevenly
- Cured blotchy
- Required hours of sanding to flatten
- And in some areas, I sanded slightly too deep, causing tone variation.
My fix idea: I may try using a fiberglass veil over the inlay before epoxy, similar to how surfboards are glassed. This might even out the resin.
What’s Next in the Shop
I’ve already got a couple more ski cores prepped, just figuring out what to do for graphics.
Cheers!
-Jon
