Things You'll Need:
- Foam Blank
- Fiberglass cloth
- Polyester surfboard resin
- Catalyst for the resin
- One or more fins
- Leash plug
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Step 1
Start designing a surfboard with a Styrofoam blank. These can be purchased at a surf shop or online. A foam blank can be carved from a large piece of Styrofoam but for the first surfboard it is much easier to buy the blank.
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Step 2
Shape the board by sanding. Shaping the board requires some advanced knowledge and it would be a good idea to get some detailed instructions at this stage. Draw the basic design on one side of the blank and cut it out with a hand saw. Shape the rails and plane down the board.
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Step 3
Use surfboard resin to fiberglass the surfboard. This resin, along with the hardener is made specifically for surfboard design and construction. The fiberglass application process gives the designer the opportunity to fill out the board in specific areas. Although the fiberglass coating is thin, it must be done properly to not create drag. It will take approximately 2 gallons of resin to complete the design.
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Step 4
Sand down the board with a fine sand paper before giving it a final smooth coat of resin. The process will have to be repeated in the area around the fin and the leash plug, but most of the design process is finished at this point.
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Step 5
Attach the fins to the surfboard. There are several types of fin designs available. Some fins break more easily than others so consider the most durable design possible. At the same time, attach the leash plug to the board. Give the whole board a finishing coat of resin and polish. You're ready to hit the waves.
