What's in a Shaping Bay?

I typed that question in a web browser and got this AI generated answer….

A surfboard shaping bay is a dedicated workspace designed for the manual or CNC-based construction of surfboards, providing the necessary dimensions, lighting, and ventilation to handle foam blanks, resins, and dust.  Ideally measuring 15' x 10' x 11', the room typically features blue, green, or black walls to enhance visibility of the white foam and is equipped with fluorescent lights positioned 4–6 inches above the board to highlight surface curves. 

Key components of a functional shaping bay include:

·                        Ventilation: Powerful air conditioning and exhaust systems to remove harmful fumes and micro-particles from fiberglass and resins.

·                        Storage: Wall racks for holding blanks and completed boards, along with shelves for tools like rasps, planers, and sanding blocks. 

·                        Safety: Protective measures such as masks, eye protection, and often a shower or drain system to clean up dust and chemical residues

Of course, I know what a shaping bay is but I thought I’d ask the question.

I made my first surfboard in my early teens in the family garage.

 That’s where my lifelong endeavor of making surfboards began…over 60 years ago. 

Having shaped boards for a number of surfboard labels over the years I’ve worked in some 18 different shaping bays. Some labels you may have heard of like Morey-Pope, William Dennis, Wilderness, Hawaiian Blades, Dick Brewer. Included in the 18 bays I’ve had 7 of my own. 

The bay at Hawaiian Blades, like most I’ve worked in, was part of a larger facility for making surfboards with a laminating room, sanding room, an area to paint in etc. Which is typical of what we call a surfboard factory, the shaping bay being part of a larger facility.

15 years ago, I was putting together the shaping bay at the property where we were flooded. That was a container. A one room set up for shaping and making surfboards. I said in a blog post back then that it may be the last one I ever have. https://drsurfboards.blogspot.com/2011/09/my-first-shaping-shack-was-lean-to.html 

Well…. that one was destroyed, and my wife and I lost our home and property due to major flooding and debris flows starting January 2023.  Three and a half years later we finally found and moved to a place we now call home. 

We moved into the place this past December. On the property is a small barn that will be the location of my new workshop. We've been doing things to the new place since we moved in and the last six weeks, I’ve been putting together my new workshop and shaping bay.

I've got some cement work done and framed up a couple walls. Dry wall and sound board and painting done. I’ve tested the shaping stand set up, lighting, and have been positioning some of tool locations etc. It’s a process, for me at least, because I like everything to have a place and be in its place. So, the complete set up takes time and effort. 

The Shop will have a separate work area alongside the shaping area. So, I’m pretty stoked having it completed soon and spending time doing what l like to do…. Making surfboards.

D.R.