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Old    wardovision (caskimmer)      Join Date: Apr 2006       06-27-2008, 10:03 AM Reply   
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When it came time to replace his old surfboard, Mike Sheldrake decided to build his own. But the former Web programmer didn’t have the sculpting skills to carve one out of foam the way professional builders do. So he used 3-D modeling software to design a snap-together deck that’s as sturdy as a conventional model and performs just as well, made from the cheapest material he could find: cardboard.

INSIDE VIEW: Cardboard slats intersect to form the frame. Photo by Brian Klutch
The board’s frame contains nearly 400 corrugated-paper slats precisely cut by a computer-controlled saw. The slats intersect at interlocking notches, forming a pattern of triangles and hexagons that provides strength by evenly dispersing force throughout the board. Sheldrake makes it watertight by wrapping it in fiberglass cloth hardened with epoxy resin (similar to traditional boards).

Sheldrake has already sold one of his creations to a pro surfer. Before he sells many more, he plans to experiment with different slat materials, such as plastic or carbon fiber, to change a board’s weight and flexibility. Eventually he hopes to offer a Web site that lets surfers customize the size and shape of boards online and then assemble them at home. That would cost far less than an ordinary board—leaving more cash for beach trips.
Old    Tyler (gotwakex45)      Join Date: Jun 2008       06-27-2008, 10:05 AM Reply   
im down for a carbon fiber one....
Old    Brian (TXSurf) (bac)      Join Date: Feb 2008       06-27-2008, 10:25 AM Reply   
Thats pretty crazy!
Old    Greg "The Hammer" (leaks)      Join Date: Oct 2005       06-27-2008, 3:32 PM Reply   
Thats got Surfdad written all over it!! Come on Jeff, I see a new project for you.
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       06-27-2008, 4:02 PM Reply   
Cardboard! :-) Ed's already done one - all 27 pounds of it. I read the build article that Sean posted up - the guy had all those pieces laser cut and then took them back and hand assembled them. I'm obsessed, but not THAT obsessed! :-) You have to applaud the builder, it's seriously cool.
Old    Smed (smedman)      Join Date: Feb 2006       06-27-2008, 4:04 PM Reply   
Bigshow has already done the cardboard board from none other than Pizza Hut boxes (although it might be bit heavier than this one). :-)

http://www.wakeworld.com/MB/Discus/messages/87668/567845.html
Old    Show (bigshow)      Join Date: Feb 2005       06-29-2008, 11:57 AM Reply   
I think this guy might have completed his board before I did the Kroger's board. He really blows me a way.
Old    matt (2onboone)      Join Date: Mar 2007       06-30-2008, 2:07 PM Reply   
i think you guys need to do carbon fiber stringer with transparent epoxy for a see through board

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