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Old     (ilikebeaverandboats)      Join Date: Jul 2007       03-27-2011, 8:32 PM Reply   
Looking into shaping a board for a summer project.
I know its do-able, but looking for some advice from guys who have done it and some websites for supplies.

First off, What all will I need?

Foam- order from? type?

Resin/epoxy/glass- type?

Fin box/fins - Im pretty set on Futures.

Rasps?- order from?

As far as shaping the board, what should I look out for? What parts need thickness for added strength?

What elements should I try to incorporate?

pretty broad, any info you got ill take!
Old     (e_rock32)      Join Date: Oct 2009       03-27-2011, 9:08 PM Reply   
Are you shaping a surfboard?
Old     (ilikebeaverandboats)      Join Date: Jul 2007       03-27-2011, 10:20 PM Reply   
yup, sorry didnt think i needed to specify
Old     (e_rock32)      Join Date: Oct 2009       03-27-2011, 10:31 PM Reply   
This is a book of free info on how to build a surfboard

and has almost everything you need

I have thought about this too:
-there are 2 main options for core - polyurethane (PU) or polystyrene (PS)
-there are 2 main options for resin - polyester (cheaper) or epoxy (5 times as expensive but much stronger)
Note that PS can only be used with epoxy

Blank cores can be bought for both PU or PS but...
Polystyrene can be bought at a hardware store (insulation) and XPS is very manageable for shaping compared to EPS
Creating a core for PU would be a lot more work and includes a balsa stringer if you use polyester

For fiberglass: shortboards use a 4 oz/yd^2 plain weave e-glass (cheaper) or s-glass (more expensive but stronger) with 2 layers on top and one on bottom, which would be really weak for wakesurfing. For extra strength I would use a heavier glass and put at least 3-4 layers on top and 3 layers on bottom double wrapping all the edges, since weight is not a huge issue

This is the cheapest and easiest option:
Buy a short fish polyurethane foam blank and shape it to your dimensions
Buy polyester resin and extra layers of e-glass
Go with a twin fin or quad fin set up so you don't have to cut through the stringer


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