I got these steps by looking at how people are making homemade wakeskates. Often they use an epoxy resin, but I decided to go with fiberglass resin. Step 1: Make a press. I went out into the shed and found a large 2x12. It was about 8' in length and I cut it in half. Note: I wanted mine to have a concave deck like trickboardz. If you want to add tip rocker and be relatively flat you would just cut the boards differently. I used a wakeboard to help me mark the curve that I wanted for the shape of the board on one of the 2x12 sections. I then cut out the shape using a jig saw, but a band saw would probably work best. Next I laid that 4' section on top of the other to mark it, then cut that curve. After that I found some old plywood sheets and screwed them down to the 2x12 halves. SO that they now had a curve. I made my press bigger than I probably needed, but if I want to make a 6' board I can. Then I added some 2x4's as supports between the 2x12's on the ends. After that the press was complete.... Note: the press was the difficult part. Once this is done you can make as many boards as you want for pretty dang cheap. Of course, my press didn't really cost me anything except for I needed to buy 6 2x4's from Home Depot. Step 2: Go to Home Depot I guess Lowe's would work as well. I bought 2 handy sheets of 1/8" birch plywood. These sheets come pre-cut 24x48". They run about $5 each. Also pick up a can of fiberglass resin. I bought the $15 size. Step 3: Fiberglass fun If you wanted to add some strength you could probably sandwich a layer of fiberglass mat in between the sheets of plywood, but I didn't. Take the two sheets of plywood, mark a basic outline of a shape on the inside of one of the boards....make sure you put the pretty side out.... Mix up your fiberglass resin and cover the shape of the board you just sketched. Do this to both boards. Then just sandwich them together and place them on the concave half of the press. I usually put a screw through the boards about where I plan on putting a fin. The goal is to get all the air out. Put the top half of the press on and use some clamps to squeeze the boards together as tightly as possible. The let it sit at least overnight, but I would suggest longer. Step 4: Shape & finish When you take the board out of the mold it will hold the shape you put it in. Because you use two sheets they hold against each other. Anyway, Shape the edges however you like. Look at some of the shapes of other boards and do what you like. Try to get the edges as symmetrical as possible, then sand and smooth. Finally, mix up some more resin and apply a coat or two to each side. Do a little wet sanding of the finish and you're there. Add some fins. Buy some grip tape for the top....Or foam traction pad. and you're done. Let me see if I can find some pics.
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