The master has experience in making surfboards for more than ten years. In this instruction, he will guide us through all the steps and subtleties of making a board. Almost every step is complemented by video instructions.
Tools and materials:
- Polystyrene XPS or EPS;
-Polyurethane adhesive;
- Epoxy resin type Resin Research;
-Add to the resin ADDITIVE F;
- Fiberglass fabric;
-Water-based paint;
-Autopolization;
-Working stand;
- Ties;
- Clamps;
-Grinder;
-Libra;
-Foam cutter;
-Sandpaper with grit from 20 to 2000;
- Tape color;
-Painting brush;
- Containers for mixing resin;
-Gloves;
-Respirator;
-Putty knife;
-Retail;
-Plywood;
-Band-saw;
Step One: Choosing Styrofoam
Surfboard can be made of two types of expanded polystyrene. Consider the pros and cons of each.
EPS-free polystyrene foam.
+
White color, not stratified, easily accessible, large blocks.
-
When damaged, it absorbs water, when grinding small balls can separate, it is necessary to dry after use.
XPS-extruded polystyrene foam.
+
It does not absorb water, does not “crumble” during grinding, does not require drying, and is readily available.
-
It can be stratified, has a blue or pink color, is available only in sheets.
The master will make this board from XPS expanded polystyrene.
Step two: gluing sheets
For the board you need material approx. 10 cm. Since there are no such sheets, the master glues two sheets of 5 cm each. First, he polishes the surface with sandpaper. Wipes with rags. It applies polyurethane adhesive over the entire surface of one sheet. The surface of the second sheet is wetted with water (the glue starts upon contact with water). Glues two sheets. Sheets the sheets with screeds and clamps through the boards. Bonding time 24 hours.
Step Three: Stringer
Stringer is a thin strip of wood or other materials that is located along the longitudinal axis of the surf. Stringer reinforces the design of the board, providing it with additional rigidity and flexibility.
Stringer master makes of plywood. The template is made according to the instructions from the Clark Foam catalog.
He transfers the template to plywood and cuts with a band saw. Processes the ends with sandpaper.
Next, you need to glue the stringer to the polystyrene foam. Cuts the polystyrene block lengthwise into two equal parts. The master uses a board as a guide. Strips the sides with sandpaper. Attaches a stringer to each side and draws a marker around it. Between the two blanks glues with a polyurethane adhesive stringer. Tightens with ties. Leaves for 24 hours.
Video in the next step.
Step Four: Trimming
After gluing, on the sides of the board with adhesive tape secures the stringer template boards. Templates serve as guides when cutting excess layers of expanded polystyrene. Pruning is done with a homemade foam cutter.
Video for step number 3, 4.
Step Five: Trim the Edges
It draws the outline of an old surfboard (or makes a template out of paper, the template can be found on the Internet). Trims both sides. Grinds one side. Then he makes her template and mirrors it to the other side. It processes the second side according to the template. Two sides turned out symmetrical.
Step Six: Grinding
Sand the board using various tools and fixtures from a grinder to sandpaper. It is necessary to achieve an almost symmetrical shape of both halves of the board.
Video of step number 5, 6.
Step seven: rails
Rails are the edges of the board from the nose to the tail (tail). The master rounds the rails. To do this, mark the surface of the board (deck) and rails. Then cuts off excess material. If the material is damaged putty it. In case a large piece is damaged, polystyrene foam is glued.
The end of the manufacture of surfboards in the second part.