Need any help or advice?+44 (0)1782 454499

PRO CASE STUDY

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
Perma-Grit Set of 8 Hand Tools in a Wallet Coarse Thumbnail
SET-8CPerma-Grit Set of 8 Hand Tools in a Wallet Coarse£67.99 /each

19mm + 32mm Cutting Discs with Arbor Thumbnail
RD319mm + 32mm Cutting Discs with Arbor£17.50 /each

CP1 Resin Infusion Catch-Pot 1.2L Thumbnail
RICP-P-SCP1 Resin Infusion Catch-Pot 1.2L£95.94 /each

Resin Infusion Silicone Connector Thumbnail
RI-SCVResin Infusion Silicone Connector£3.90 /each

EC.4 Compact Composites Vacuum Pump + UK Lead Thumbnail
VP-EC4-UKEC.4 Compact Composites Vacuum Pump + UK Lead£276.00 /each

Total £0.00
STARTER KIT(S)
Resin Infusion Starter Kit Thumbnail
SK-RIResin Infusion Starter Kit£174.00 /kit

Uni-Mould Complete Mould Making Kit Large (3.3sqm) Thumbnail
SK-UM-L-KITUni-Mould Complete Mould Making Kit Large (3.3sqm)£314.40 /kit

Total £0.00
MATERIALS & CONSUMABLES
MEKP Catalyst 500g Thumbnail
MEKP-05MEKP Catalyst 500g£5.94 /pack

ST150 Vacuum Bagging Sealant Tape 15m Each Thumbnail
VBST150ST150 Vacuum Bagging Sealant Tape 15m Each£5.99 /roll

S120 Advanced Board & Mould Sealer 1L Thumbnail
S120-1S120 Advanced Board & Mould Sealer 1L£155.10 /pack

PU600 High Density Model Board T=100mm, 500 x 1500mm Thumbnail
PU600-075-100PU600 High Density Model Board T=100mm, 500 x 1500mm£304.20 /block

Resin Infusion Spiral Medium Flow 10m Coil Thumbnail
RISP-M-10Resin Infusion Spiral Medium Flow 10m Coil£4.20 /pack

PP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack Thumbnail
AFPP180-152-5PKPP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack£12.00 /pack

VB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack Thumbnail
AFVB160-152LFT-5PKVB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack£14.88 /pack

FM100 Infusion Mesh (1050mm) 5m Folded Pack Thumbnail
AFFM100-105-5PKFM100 Infusion Mesh (1050mm) 5m Folded Pack£14.40 /pack

IN2 Epoxy Infusion Resin SLOW 5kg Kit Thumbnail
EP-IN2-S-5IN2 Epoxy Infusion Resin SLOW 5kg Kit£72.52 /kit

210g 2x2 Twill 3k Carbon Fibre Cloth (1000mm) Thumbnail
CF-22-210-100210g 2x2 Twill 3k Carbon Fibre Cloth (1000mm)£25.20 /linear metre

Easy-Lease Chemical Release Agent 500ml Thumbnail
ELRA-05Easy-Lease Chemical Release Agent 500ml£19.80 /pack

Lantor Soric SF Infusion Core (1270mm) T=3mm Thumbnail
SORIC3Lantor Soric SF Infusion Core (1270mm) T=3mm£14.94 /linear metre

Total £0.00

PRO CASE STUDY

DJR's Full Carbon Fibre NITRO Jet Ski

When DJR's Dan Rowan wanted to push the envelope of freestyle jet ski performance he realised that the only way to get exactly what he wanted would be to design and make his own hulls.

As a European Freestyle Champion, Dan already had a clear vision of what needed to change with current hull construction in order to make the perfect freestyle ski; he knew where he wanted to lose weight and where he wanted more strength and he knew what needed to be designed into the hull right from the start in order to build it up into a championship winning ski.

Although Dan and his team had composites experience from years of modifying and fitting out high performance skis, what they didn't have was experience of was building a complex structure like a jet ski hull right through from the design stage to the finished product, and so this was where Dan turned to Easy Composites.

Dan already had a proven prototype hull design, a realistic budget and an uncompromising approach to the quality and performance that the finished ski must achieve. Given these parameters we suggested working with a CAD designer to produce a solid model of all the ski components which could be turned into individual models for each for the ski mould patterns. CNC machining the patterns from a CAD design ensured the smooth lines and perfect symmetry that are almost impossible to achieve when building patterns by hand, especially at this scale.

To make the moulds we recommended our Uni-Mould tooling system which would allow individual moulds to be made in as little as one day with minimum shrinkage or distortion, important if Dan was going to maintain the perfect lines of his CNC machined patterns. The vinylester tooling gelcoat used in the Uni-Mould system also ensured the moulds would be fully compatible with the epoxy resin that would be needed to make the high spec hulls.

Meeting Dan's requirement for maximum strength and minimum weight meant maximising the fibre-to-resin ratio in the laminate, as well as making use of structural core materials within the construction and so vacuum resin infusion was chosen as the production method for the hulls themselves.

Easy Composites supplied DJR with vacuum pumps, equipment, consumables and materials for the resin infusion process and provided the ongoing support Dan needed to perfect the resin infusion process and produce genuinely expert-level carbon fibre components which met or exceeded the performance he set out to achieve.


NITRO JET SKI SPECIFICATION

ConstructionResin infused epoxy matrix high strength carbon throughout. Post cured.
Bare hull weight16kg (top and bottom, unbonded)
Hood weight3kg
Hull length210cm
Hull width68cm

Click here for full specification on DJR’s NITRO hull

ABOUT DJR

DJR

Headed up by Dan Rowan, himself a freestyle jet ski European champion, DJR have been refining and fitting out championship winning jet skis since 2014.

Driven by the desire to take the performance of their skis even further, in 2018 DJR made the decision to bring the manufacture of their hulls in-house and so began the project to produce the NITRO, one of the most single-minded, high performance jet skis on the market.

DJR

"Easy Composites have supported us through the entire process from CAD design, machining, tooling and production. It’ s been a long road with plenty of learning along the way but I now believe we are producing one of the best jet ski hulls on the market and we couldn’t have done it without the support of Easy Composites."

"We are now a dedicated composites manufacturing business and we could not have achieved this without Easy Composites. I am proud to say that we manufacture everything with their products and we rely on their excellent service, technical support and high quality materials every day and I look forward to working with them for many years to come."

Dan Rowan, Managing Director
DJR Ltd / NITRO Composites

"Working with Dan and his team has been an absolute pleasure. They were clear with their vision and realistic about the time, effort and budget that would be required to see it through to realisation. The standard of work that DJR now produce is as good as anything we’ve ever seen."

Paul Statham, Technical Director
Easy Composites Ltd


CONTACT INFORMATION

DJR Ltd
6 Tower Close
Wrexham Industrial Estate
Wrexham
LL13 9WB

Phone+44 1978 669073
Emailsales@djrltd.com
Websitewww.djrltd.com
Facebookfacebook.com/djrjetski
Instagram@djrltd

DISCUSSION (0)

Please share any questions or comments you may have about this video tutorial.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
Perma-Grit Set of 8 Hand Tools in a Wallet Coarse Thumbnail
SET-8CPerma-Grit Set of 8 Hand Tools in a Wallet Coarse£67.99 /each

19mm + 32mm Cutting Discs with Arbor Thumbnail
RD319mm + 32mm Cutting Discs with Arbor£17.50 /each

CP1 Resin Infusion Catch-Pot 1.2L Thumbnail
RICP-P-SCP1 Resin Infusion Catch-Pot 1.2L£95.94 /each

Resin Infusion Silicone Connector Thumbnail
RI-SCVResin Infusion Silicone Connector£3.90 /each

EC.4 Compact Composites Vacuum Pump + UK Lead Thumbnail
VP-EC4-UKEC.4 Compact Composites Vacuum Pump + UK Lead£276.00 /each

Total £0.00
STARTER KIT(S)
Resin Infusion Starter Kit Thumbnail
SK-RIResin Infusion Starter Kit£174.00 /kit

Uni-Mould Complete Mould Making Kit Large (3.3sqm) Thumbnail
SK-UM-L-KITUni-Mould Complete Mould Making Kit Large (3.3sqm)£314.40 /kit

Total £0.00
MATERIALS & CONSUMABLES
MEKP Catalyst 500g Thumbnail
MEKP-05MEKP Catalyst 500g£5.94 /pack

ST150 Vacuum Bagging Sealant Tape 15m Each Thumbnail
VBST150ST150 Vacuum Bagging Sealant Tape 15m Each£5.99 /roll

S120 Advanced Board & Mould Sealer 1L Thumbnail
S120-1S120 Advanced Board & Mould Sealer 1L£155.10 /pack

PU600 High Density Model Board T=100mm, 500 x 1500mm Thumbnail
PU600-075-100PU600 High Density Model Board T=100mm, 500 x 1500mm£304.20 /block

Resin Infusion Spiral Medium Flow 10m Coil Thumbnail
RISP-M-10Resin Infusion Spiral Medium Flow 10m Coil£4.20 /pack

PP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack Thumbnail
AFPP180-152-5PKPP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack£12.00 /pack

VB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack Thumbnail
AFVB160-152LFT-5PKVB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack£14.88 /pack

FM100 Infusion Mesh (1050mm) 5m Folded Pack Thumbnail
AFFM100-105-5PKFM100 Infusion Mesh (1050mm) 5m Folded Pack£14.40 /pack

IN2 Epoxy Infusion Resin SLOW 5kg Kit Thumbnail
EP-IN2-S-5IN2 Epoxy Infusion Resin SLOW 5kg Kit£72.52 /kit

210g 2x2 Twill 3k Carbon Fibre Cloth (1000mm) Thumbnail
CF-22-210-100210g 2x2 Twill 3k Carbon Fibre Cloth (1000mm)£25.20 /linear metre

Easy-Lease Chemical Release Agent 500ml Thumbnail
ELRA-05Easy-Lease Chemical Release Agent 500ml£19.80 /pack

Lantor Soric SF Infusion Core (1270mm) T=3mm Thumbnail
SORIC3Lantor Soric SF Infusion Core (1270mm) T=3mm£14.94 /linear metre

Total £0.00

ABOUT DJR

DJR

Headed up by Dan Rowan, himself a freestyle jet ski European champion, DJR have been refining and fitting out championship winning jet skis since 2014.

Driven by the desire to take the performance of their skis even further, in 2018 DJR made the decision to bring the manufacture of their hulls in-house and so began the project to produce the NITRO, one of the most single-minded, high performance jet skis on the market.

DJR

"Easy Composites have supported us through the entire process from CAD design, machining, tooling and production. It’ s been a long road with plenty of learning along the way but I now believe we are producing one of the best jet ski hulls on the market and we couldn’t have done it without the support of Easy Composites."

"We are now a dedicated composites manufacturing business and we could not have achieved this without Easy Composites. I am proud to say that we manufacture everything with their products and we rely on their excellent service, technical support and high quality materials every day and I look forward to working with them for many years to come."

Dan Rowan, Managing Director
DJR Ltd / NITRO Composites

"Working with Dan and his team has been an absolute pleasure. They were clear with their vision and realistic about the time, effort and budget that would be required to see it through to realisation. The standard of work that DJR now produce is as good as anything we’ve ever seen."

Paul Statham, Technical Director
Easy Composites Ltd


CONTACT INFORMATION

DJR Ltd
6 Tower Close
Wrexham Industrial Estate
Wrexham
LL13 9WB

Phone+44 1978 669073
Emailsales@djrltd.com
Websitewww.djrltd.com
Facebookfacebook.com/djrjetski
Instagram@djrltd

DISCUSSION (0)

Please share any questions or comments you may have about this video tutorial.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

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