How to Cut a Surfboard Out of Foam

If you want to make a surfboard, cutting the surfboard out of foam is one of the most difficult parts. It's important to get it right the first time because a mistake could be costly.

Difficulty: Challenging

Instructions

Things You'll Need:

• Polyurethane foam block
• Jigsaw
• Plywood
• Planer

1. Purchase a polyurethane blank that's close to the size you want your finished surfboard to be. Most companies that sell surfboard supplies tend to be near surfing hot spots. Factor in shipping costs if you live away from these locations.

2. Make a template from plywood. It's best if you already have a surfboard you want to use as a template. Line up the stringer (middle line) of your surfboard with the edge of the plywood. Use a marker to trace the board. Cut the shape out with a jigsaw.

3. Use your template to mark the areas you want cut on your foam block. Cut the shape out using either a jigsaw or hand saw.

4. Use a planer to reduce the thickness of the foam. Work from the tail to the nose. You should now have a surfboard.

Tips & Warnings

• Go slow to make sure that you do everything correctly.
• Make your board suitable for the types of surf conditions you encounter where you surf the most. This ensures that you get more use from your board.
• When you make a surfboard at home, there is a big mess to contend with. There's hardened resin on the ground and an unhealthy fiberglass dust in the air. This is permanent. If possible, it's best to make a surfboard in a special work area designed for that purpose.