How to: Fiberglass a Skateboard

Fiberglass skateboards were popular in the 1970s, and their popularity continues among some purists. They are stronger, lighter and more flexible than wood boards, as well as being less susceptible to damage from humidity. Moisture and humidity can separate the ply layers of a wooden skateboard, greatly compromising its rigidity. A fiberglass board is relatively straightforward to produce, using a simple mold and some sheets of fiberglass cloth. It can be sanded and finished by hand for a professional look.

Things You'll Need

  • 3 plywood planks 4-feet by 1-foot by 3/4-inch
  • Pencil
  • Jigsaw
  • Dust mask
  • Protective gloves
  • Fiberglass sheets
  • Epoxy resin
  • G-clamps
  • Craft knife
  • Sandpaper
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Instructions

    • 1

      Draw the outline of the skateboard on one of the plywood sheets. The outline must be accurate and symmetrical, so drawing it freehand is not recommended. Trace around an existing skateboard if necessary.

    • 2

      Cut out the skateboard shape using the jigsaw, staying well inside the outline. Use sandpaper to take off the last few millimeters. This piece will form the walls of the mold so it needs to be accurate.

    • 3

      Center the plywood with the cutout on one of the other lengths of plywood, forming a board-shaped trough, or mold, 3/4-inch deep. Clamp the two pieces of plywood together.

    • 4

      Put on the gloves and dust mask. Mix the epoxy resin in its container, according to the manufacturer's instructions.

    • 5

      Dip the fiberglass sheets in the resin, one by one, and lay them into the mold. Work slowly and methodically, ensuring the sheets fully contact the edges of the mold, leaving no gaps or air bubbles. When the mold is completely full. Clamp the third sheet of plywood onto the other two.

    • 6

      Allow the fiberglass board to dry, then release the top and bottom plywood sheets before punching the board out of the cut-out sheet. If the board will not come out straight away, flex the panel to separate the fiberglass from the mold all the way around.

    • 7

      Trim off any overhanging fiberglass sheets from the edges of the board using the craft knife. Any excess will be very thin and brittle, so it will cut with relative ease.

    • 8

      Sand the board smooth across all of its edges and it is ready to be fitted with mounting hardware.