Things You'll Need:
- Planer
- Jigsaw
- Electric sander
- Sand paper
- Foam blank
- Fin kit
- Electric drill
- Resin with catalyst
- Workhorse
- Fiberglass cloth
- Hot coat resin
- Thin sheet of plywood
- Squeegee
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Step 1
Make a template for your surfboard. Model your pattern after surfboards you've tried. You can even use another surfboard to trace a pattern. Think about things like nose and tail design, rail shape, length and width when designing your surfboard.
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Step 2
Cut out your template from a thin sheet of plywood using a jigsaw. Be sure the plywood is locked in place before you start cutting.
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Step 3
Pick up a blank foam core. Check the foam density level and get a blank that supports your body weight.
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Step 4
Shape your board. Place the template on top of your blank and trace a pattern on both the top and bottom of the form. Cut the blank using a jigsaw.
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Step 5
Use an electric planer to shave away foam to desired shape. Shape the rails, nose and tail and shave the top and bottom of the blank to achieve the desired density. You may have to use a hand planer on the nose and tail to fine tune the shape.
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Step 6
Flip your board over onto the bottom side and clamp it onto the workhorse. Roll a sheet of fiberglass over it, making sure some extra hangs over the edge of the blank and the rails.
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Step 7
Mix the resin and catalyst and pour over the center of the board, and spread the resin across the board using a squeegee. Fold the fiberglass cloth over the edges as you work in the resin. Let dry overnight and repeat for the deck.
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Step 8
Get a fin kit and install fins to the bottom of your board.
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Step 9
Apply a layer of hot resin coat to the bottom of the board. Let dry and repeat for the deck of the board.
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Step 10
Use an electric drill to drill a hole on the bottom of the board. Cut away any excess foam and add some resin mix to the hole. Insert a leash plug into the hole and cover with more resin. Let dry for about 3 hours.
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Step 11
Make sure the board is free of dust and then sand it using an electric sander. Wet down the board, and sand it using wet-dry sandpaper to create a smooth and glossy finish.
Comments
samuraiboards said
on 2/6/2009 Aha!
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HeatherRoseZ said
on 1/6/2009 How long deos this process usually take? I am only 20 years old and was really thinking about making myself a surf board.. I already have two... one is in really bad shape was thinking about fixing it to... Do you think this could be a project done with just one person??