How to Create Your Own Surfboard

Surfing is enjoyed by people everywhere.

Surfing is an ever-growing sport that is popular among young and old people from all areas of the world. The ability to surf on beautiful beaches and ride waves that tower and curl over is as enjoyable as it is active. It can sometimes be expensive to buy new surfboards, especially for new surfers who may have to change their surfboard often. Learning how to create your own surfboard makes it convenient to create something that represents your style and character whenever you need it.

Things You'll Need

• 3 x fluorescent lights
• Measuring tape
• Thin plywood
• Pencil
• Safety mask
• Safety goggles
• Wooden workhorse
• Foam blank
• Jigsaw
• Electric planer
• Hand planer
• Finger-sized planer
• Steel mesh
• Dust brush
• Fiberglass cloth
• Straight pins
• Scissors
• Latex gloves
• Masking tape
• Fiberglass rope
• Surfboard resin & catalyst
• 3 x plastic squeegees
• Hot coat resin & catalyst
• 3 x wide paint brushes
• Electric drill
• Leash plug
• Electric circular sander
• Coarse sand paper
• Wet sand paper

Instructions

Design and Create

1. 

   Plywood is often used to create surfboards.

   Choose a space to work in and set your fluorescent lights up to have a good view of what you are creating. Decide what style of surfboard you wish to create and what design you want to implement into it. Having the image in your mind or on paper makes it so much easier when you start to create your own surfboard. Take the super thin plywood and place it on the floor. With a pen or pencil, mark the template of the surfboard or use an existing surfboard to trace around.

2. Plug in the jigsaw and apply the safety mask for health and safety purposes. Cut out the shape using the jigsaw to have your template ready to work on. Pick a foam blank that represents your choice and has a strong density. In your workspace under fluorescent lights, have your measurements on a piece of paper so you can refer to them in the process.

3. 

   Work in an organized and well-lit place.

   Place the blank on top of the wooden workhorse with the bottom side facing up. Set your template on the blank and line it up correctly. Pencil the shape on each side of the blank to get the shape of your surfboard. Apply your safety goggles and use the jigsaw once more to cut around this new template, leaving 1/8 inch gap around the pencil markings.

   Place the blank in the holding of the wooden workhorse and set the planer's depth to 1/3 inch. Run the planer along the edges of the blank avoiding the pencil markings and continue this until near perfect.

4. Set the workhorse to 1/6 inch and slowly place the board bottom side up. Plane the board carefully from tail to nose until it is 1/2 inch thicker than the planned thickness. Slip the blank and plane the top with the hand and finger planer. Plane until the soft layer of foam can be found through the hard foam.

5. Form the curve of the rails with the planer and once happy, use the steel mesh from tail to nose to achieve your desired shape. Round the front of the bottom rail area and make the back area sharper and pointed. The fluorescent lights in your working area can intelligently pick up any flaws that sunlight will not find.

Protecting and Coating

1. 

   Always wear health and safety gear.

   Sweep all of the dust off the bottom of the board with the dust brush. Place electric tools away and clear a safe working area for the new part of the process. Roll out the fiberglass cloth and hold it in place with straight pins, allowing it to hang slightly over the edges. Trim the cloth with scissors and leave the fiberglass cloth to hang over by 2 inches. Cut some narrow V shapes at the tails to avoid difficult overlapping when folding.

   Apply latex gloves and take 27 fluid ounces of resin and a few drops of catalyst in a glass until a thick consistency is formed. Pour in the center of the board along with the squeegee which should then be worked into the fiberglass cloth.

   Fold over the fiberglass cloth and secure over the edges. Check that the cloth is wet and secured in place while you remove any drips with some squeegee. Leave the resin to cure for at least a day. Turn the board over and dust off the deck when the resin has cured. Roll out the fiberglass cloth and use the glassing method again, leaving the resin to cure once more.

2. Apply the fins by cutting out 5 inches by 2 inches of fiberglass cloth in sox pieces. Mark on your board where you want the fins to be placed with a pencil, it's helpful to look at other surfboards for help on this.

   Place your fins carefully with precise angling and hold in place with masking tape. Put some gloves on and prepare 17 fluid ounces of resin along with the added catalyst. Dip all of the fiberglass rope into the resin, except the part you are holding in your hand.

   Remove the wet fiberglass and squeeze it to remove at least half of the resin. Locate the left fin and place the rope on the board in this area. Pull the rope back until the end of the rope is 1/2 inch longer than the fin itself.

3. 

   Use an electric sander to remove lumps and bumps.

   Cut the rope with the scissors. repeat on each fin and place the six pieces of fiberglass cloth on the sides of each fin to keep a secure hold. Clean any excess dripping with the squeegee and leave the resin to cure for another day.

   Place the board fin side up and prepare 35 fluid ounces of hot-coat resin with catalyst; this is to protect the board further.

   Pour some of the resin on the board and work in with a paintbrush, coating the fins, too. Pay caution to the heat of this resin as it can get very hot. Wipe any drips with a cloth. Leave to cure for a couple of hours and repeat for the alternate side of the surfboard.

4. Drill a hole for your leash plug at least 3 inches from the tail and near to the stringer. Prepare 3.5 fluid ounces of hot-coat resin with catalyst in a cup and pour into the hole. Place the leash plug into the hole and add some more resin. Carefully push the plug farther into place and leave to cure until hard.

5. Plug in the electric sander and put on your safety mask and glasses. Sand the entirety of the board until a smooth and lustrous texture is achieved. Try to sand out all lumps and bumps on the board. Wet some sand paper in water and do the same. This is to avoid any irritating to the skin after being in contact with your surfboard. Add some painting and designs to complete the look if you wish.

Tips & Warnings

• Before applying this technique to create your own surfboard, you should have an understanding of the density, design, shape, thickness, weight and number of fins you want your board to have.

• The hot-coat resin can become extremely hot, so be careful not to burn your skin.

• Always wear the appropriate health and safety gear when using electrical appliances.

References

• Board Building - Surfboards, Sailboards, Kiteboards
• Information on the Surfboard - What's what?