So you want to make a surfboard? Post 2

The place you have to start is the core…. the blank. Usually a foam, either polyurethane or EPS, that has been molded or cut specifically for making surfboards. Surfboard blanks come in a range of sizes so getting a blank that will be close to the size of board you plan to make is important. If you are making a 6’6 then you’d get a blank an inch or two longer, as well, if you wanted to make a 9’6 you’d get a blank that was 9’8 in length.

Blanks are molded with what we call a natural rocker that can be adjusted and held in place with the wood stringer that is glued into the length of the blank. Without a stringer blanks can and do loose some rocker and without a stringer it’s very difficult to add or subtract rocker into your shape.

You need the proper tools to shape a surfboard once you’ve gotten a blank. Though an electric plane is what is used in the industry it is possible to use hand planes and sand paper to get the job done.

I generally start with the outline when shaping. A nice curve drawn on the blank from a template that has no flat spots or bumps and can be duplicated on both side of the blank making a symmetrical left and right side is how it’s done. After the outline is drawn on the blank you cut out your outline and true up your cut with a plane and sand paper making sure again that there are not flat spots or bumps in the outline.

After the outline is finished milling your blank to thickness and foil interests is the next step, and the process where the inexperienced and experienced shaper will differ in approach. The inexperienced will simply plane the blank to desired thickness and move on to the next step. However, surfboard blank molds are made from plugs that are oversized in length, width and thickness for a particular sized surfboard. But don’t quite have the exact foil or foam volume distribution for anything but a very generic shape. So the experienced shaper will redistribute the blanks foam volume to get the foil to his liking, both for performance and aesthetic interests.

Because it’s possible to copy a certain board outline and have a nice curve to work with in outlining a surfboard almost anyone if taking their time can put an acceptable plan shape… outline.. on a blank. Getting just the right foil cut into a blank takes much more effort which comes from repetition of the process, the touch and sight that is developed from loads of repetition.

D.R.

Photo by David Puu