Home Made Board Thread

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birdfood started the topic in Thursday, 23 Apr 2020 at 10:36pm

Show us your home made boards! Here's my first three from right to left (took me about 2 years from first to last):

Board 1 5'10"x21x2 3/4 PU/PE horrible cut lap gouges, heaps of volume, I rode it pretty much exclusively for the 12 months after making it. I'd still be riding it now but it's out of action with a busted fin.
Board 2 5'10"x20x2 1/2 PU/PE ugh I seem to have a habit of doing something the second time much worse than the first. Super boxy rails. I haven't ridden this one much. Cut from a fish blank so it's got a very flat rocker.
Board 3 5'8"x19x2 1/2 PU/Epoxy with an acrylic fade brushed on. I still ride this one. Again, this one is cut from a fish blank. I tried to increase tail rocker and shape in double concaves through the fins and a vee off the tail. It technically has all of these features but at the confluence of the three it's got these weird hip bone curves right where the side fins are facing outwards from the bottom. I used peel ply for this one and a foam roller. No sanding and you can see the squeegee lines in the hot coat.

Board 4 5'2"x19x2 1/2 I re-shaped a factory second machine shape that was very kindly given to me when I when to buy a marko blank. Stringerless EPS with two layers of 4oz on the bottom and three layers on the deck. I used peel ply again this time with a squeegee and a roller for the rails. This is my go to board (or the fade thruster). It's super light and super fast and realistically it's pretty uncommon to get waves on the GC that this board can't handle. I hand sanded the rails and bottom using wet sand paper and left the deck unsanded.

Board 6 5'10"x19x2 1/3 I'm currently building. I've had the machine shaped blank for about 18 months but now with the lock down I've got a pretty good excuse to finish it. First time using the Surf Flex resin from Sanded and I'm pretty impressed with it. Coming back the following day after laminating it was really easy to cut through the glass with a razor so I reckon I might attempt a cut lap again on Board 7 or 8. This will be my most "conventional" short board. Not sure how I'm going to find riding it as I'm not used to having to generate speed. Definitely the best shape out of the boards I've done and I'll be almost certainly getting my next boards machine shaped.


I'm finding the glassing to be the part of the process I'm most interested in. All of my boards have mistakes and bubbles and insects in the glass. I'd love to be able to do this more often but need to work out how to make it cheaper / get more time. I reckon once I'm past board 10 I might be less sentimental about them and will probably start trying to sell them used to help fund the next one.

velocityjohnno's picture
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velocityjohnno Monday, 18 Apr 2022 at 3:47pm

yep have done that too, MDF template & router. My router bit is not long enough!

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velocityjohnno Monday, 18 Apr 2022 at 3:47pm

but it cuts *so* nice

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velocityjohnno Monday, 18 Apr 2022 at 3:57pm

I also find if I exactly copy the outline desired on a template, the template sees the router cut a little away from where it should at nose and tail - no biggie, the board is thinnest there and easy to carve that foam down to true outline. I use router in it's square base for stability, so I guess the difference comes from that.

Edit: the maths: think of the square base as a line, intersecting a curve. At any point it would cut the derivative of the curve dy/dx.

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velocityjohnno Monday, 18 Apr 2022 at 3:52pm

oh yeah, the rocker machine I built when young (no internet: had to design and build it using only WL's description in Tracks!) is nearly 28 years old now, and still cuts perfect to the milimetre. Bottom and deck rockers suddenly got consistent!

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velocityjohnno Monday, 18 Apr 2022 at 4:04pm

Highlight in recent years was putting chambered paulownia blank - that we made ourselves by clamping lengths - on it and cutting surfaces 100% perfect prior to shaping of rails, bottom contours with my son.
That stuff is just so much nicer on the human body to work with, and you can walk it through the house, haha.

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udo Monday, 18 Apr 2022 at 5:02pm
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udo Monday, 30 May 2022 at 12:45pm
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udo Sunday, 14 Aug 2022 at 6:55pm

In the Factory with Pieter
A Great Insta page

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philosurphizing... Sunday, 28 Aug 2022 at 12:58pm

Talk of Swaylocks possibly folding.
It seems as though some people are ok with all that knowledge just disappearing.
Makes no sense to me.
https://www.swaylocks.com/forum/110183/what-does-swaylocks-need?page=8

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velocityjohnno Sunday, 28 Aug 2022 at 7:34pm

Cripes, that would be like the Burning of the Library of Alexandria, of back yard board shaping.

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udo Thursday, 22 Sep 2022 at 1:04pm

Tips from Big Pieter


I focus's picture
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I focus Friday, 23 Sep 2022 at 3:16pm

Hmm washing hands in acetone, no mask, but still lovely work how's running the hand down the rail to wrap the lap loved it.

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udo Friday, 23 Sep 2022 at 4:27pm

Fark i cringed at the Acetone hand washing....its Evil shit
Great Home business setup.putting out old school work...love a good Gloss coat
Boards arent Cheap but def getting Top Quality...he only likes to do 2 per week..
https://pieter.com.au/

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baphomet Thursday, 13 Oct 2022 at 2:35pm
velocityjohnno wrote:

Cripes, that would be like the Burning of the Library of Alexandria, of back yard board shaping.

I agree: I say without irony that it'd be a loss. Such a weird and wonderful place, even in concept: an early 2000's web forum, of not just surfers, but shapers, and not just shapers, but backyarders. That's a three way Venn diagram with a very small space of intersection, you'd think: a subculture of a subculture of a subculture.

I made a separate post asking about it (and so I apologise if this constitutes spam), but I'd love to know what the ultimate decision was about the future of the site. Caus' right now, it's down.

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udo Saturday, 15 Oct 2022 at 5:46pm


~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Indeed the optimal foam mix recipe seems secretive. From what i can find, blank manufacturers are using a high pressure mixing gun to pour the foam into the mold for the best possible mixing, but also for practicality. These high pressure mixing gun machines are way out of my budget and only make sense for large productions.

So I'll probably never be able to acheive the same results as an industrial blank.

However the blanks im making are plenty for my needs. The foam density is evenly spread out throughout the enitre blank without bubbles (by using cooking wax realease paper instead of saran wrap, seems to let the air out). The blanks sands as good as a normal blank. Once i sand the crust off the blank, the texture of the foam is almost identical to a normal Blank. Adding a white pigment to the mix makes the blank almost white.

The mold weighs around 350 kilos, took 3 days to make, and cost me around 250$ in materials. Once the mold is made, the process of making the blank is fast, 10 minute prep work, 2 minutes of mixing and pouring, and 10 minutes of curing. I can start shaping it 20 minutes after it is poured. I could technically pop out a blank every 30 minutes. Right now a blank is costing me 40$ instead of $150+ if i import them (I live in a carribean island with high import and tax fees).

As Mako224 mentioned you can select a variety of foam density to your liking. Now, i'm trying to figure out if just by increasing the amount of liquid into the mold, does it increase hardness of the foam? techinically it increases density but does it also change the hardness of the foam? for example if i poured 1 liter of 2lbs density foam into a mold, would i get the same density/ hardness as 1 liter of 4lbs into the same mold? Both blanks would weight the same, at first it seems like the 4lbs density foam would be harder but the 2lbs foam expands twice as much, so that should create more pressure in the mold which should help with density/hardness... ? So thats where im at now. Like stonerburner said "precise mixing volume and internal mold pressure are ingredients in the secret sauce"

The mold i made was to create kitesurf blanks which is why it is so small, I would love to make a bigger one for surfboards, however the mold would be bigger and a lot heavier. Something like that is very hard to move once made so it has to be created where is going to stay, not sure if i want another massive box full of concrete in my basement right now.

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udo Sunday, 16 Oct 2022 at 1:35pm

Another Fine Vid from Mr Shrednaught over the West

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udo Sunday, 16 Oct 2022 at 2:38pm

FCS Plug Fix ~ The Proper Way

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linez Sunday, 16 Oct 2022 at 4:17pm
udo wrote:

Another Fine Vid from Mr Shrednaught over the West
https://www.youtube.com/watch?v=ZfczJzBJFQ8

Yeah udo, his vids are good value.. very informative. Welcoming to questions too.