DIY Fiberglass Skateboards

As the sport of skateboarding has increased in popularity and involvement since the 1960s, the equipment used by riders has changed drastically. While many different manufacturers and skate deck designs exist today, riders have started crafting their own personal boards. Building a skateboard yourself is a rewarding task as you create something from nothing. If you would like to build your own fiberglass skateboard, determine what function this deck will serve. Downhill skate decks are shaped much longer than traditional street boards, for instance.

Things You'll Need

  • Paper
  • Pencil
  • Scissors
  • 2 sheets 3/16-inch birch aircraft plywood
  • 7 ounces urethane glue
  • Circular saw
  • Curved ramps
  • Wood clamps
  • Screws
  • Electric drill
  • Epoxy resin
  • Hardener
  • Mixing bucket
  • Fiberglass cloth
  • Belt sander
  • Base router
  • Griptape
  • Skateboard hardware package (trucks, bolts, bearings)
  • Riser pads (optional)
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Instructions

  1. Constructing the Deck

    • 1

      Sketch the basic shape of the skateboard on a piece of paper, using exact dimensions. If available, use an existing skate deck to help you create the specific shape. Otherwise, your skate deck should fall somewhere between 7 to 8 inches wide and 30 to 40 inches long. Cut this shape out of the piece of paper when you are finished.

    • 2

      Set the first piece of aircraft plywood in front of you. Pour urethane glue on one side of this plywood, then spread evenly across the board with a plastic scraper. Place the second piece of plywood next to you and wet the surface. Attach the wet surface of the second plywood to the urethane-soaked top of the first sheet.

    • 3

      Place your board on a curved ramp while the urethane glue dries. Drill holes around the perimeter of your plywood sheet to hold these two sheets together, then clamp the middle of the board to the bottom of the ramp. Likewise, use a second clamp near the top of the ramp to force pressure onto the end for the curved tail. If you would like to create two curved ends for this board, repeat this process for the other end. Let the board sit overnight, then unscrew each of the connections and take off each of the clamps.

    • 4

      Cut the excess glue from the sides of your two plywood sheets with a craft knife. Place the paper outline of your skate deck on top of the plywood sheets, then trace with your pencil. Use a circular saw to cut the shape of your plywood sheets into the shape of your desired board.

    • 5

      Lay the fiberglass cloth sheet over the bottom of your skate deck. Cut this cloth down to an appropriate size to match your deck, leaving about 1 inch of room around the perimeter. Mix the epoxy resin with the hardener, then apply evenly to the bottom of the board. Attach the cut piece of fiberglass cloth to the bottom of the deck, using a plastic scraper to smooth out any bubbles that may appear. Let dry.

    • 6

      Cut the excess fiberglass cloth from your skate deck once everything has dried. Use a belt sander to create a smooth surface on the bottom of your fiberglass deck. Flip your deck over, then use a base router to smooth out the sides of your skate deck. Repeat for the opposite side, creating rounded edges for your board.

    • 7

      Position a piece of griptape on the top of your skate deck. If you wish to make any designs in this grippy material, do so at this time. Otherwise, peel the griptape from its attached sheet and carefully lay it down on the top section of the board. Run the handle of a screwdriver around the perimeter of the skate deck to secure. Use a craft knife to cut the excess griptape from your board.

    Assembly of the Skateboard

    • 8

      Drill four holes at each end of the skate deck to attach the trucks, or axles. Use a riser pad to get the precise measurements necessary for this procedure.

    • 9

      Position a riser pad over each of the holed sections of your skateboard. Riser pads help elevate the trucks, reducing the amount of rub against the board during sharp turns. These aren't necessary parts, but they help tremendously with larger wheels.

    • 10

      Place a truck over each of the riser pads, ensuring the four holes line up with all the parts. Open your skate hardware package and secure each of the trucks. Use a skate tool to tighten the four bolts that hold each of these trucks in place. Likewise, adjust the kingpin of your truck to loosen or tighten to your liking.

    • 11

      Slip a bearing over the end of one of the trucks. Place a wheel on top of this bearing and apply pressure until the bearing snaps into place. Pull the wheel off and place a secondary bearing onto the truck. Apply pressure to the opposite side of the wheel until the second bearing snaps into place. Repeat this process for the remaining bearings and wheels.

    • 12

      Secure each of the wheels to the trucks with the provided bolts. Each set of trucks comes standard with the bolts necessary. Take your new skateboard for a spin and make sure everything is set up to fit your needs.