Electric Hydrofoil (EFoil)
Function: To build a surfing hydrofoil capable of moving at over 40 knots for over an hour under it’s own power
Inspiration: I have had a surfing Hydrofoil in my garage for almost 3 years now. It has been sitting there, tempting me, and I finally gave in and decided to do something with it. After a bit of research, I learned that it was possible to electrify it.
Methods: In the early stages of the build. I have ordered a custom 72V 60AH Li-Ion Battery, and have received the custom ESC and 10kw 120Kv motor. Both of these have been waterproofed with water cooling lines attached, but until I have finished the CNC I cannot make much progress as I have no skill with surfboard shaping. My goal is to carve custom foam board layers, and the fiberglass them together to make the final board.
Outcome: TBD
Failures and challenges:
The original board I was going to use is much too small. It cannot hold the battery, and there is no chance I will be able to fit the ESC and other sensitive equipment inside of the board, as it is only 3” thick. My final custom board design is over 8” thick.

Custom Battery, Weighs 21kg

A similar motor to the one I ordered, fully submersible, IP68 waterproof

Top View of the custom board, with battery compartment

Bottom View of the board, with fix box/holes for wires

Our end goal (Credit: Fliteboard)

Milling a slot in a 3d printed part
New and improved motor mount, extends the prop 8" further underwater

The board prior to its first test