How to Make a Foam Core Skimboard

A skimboard is similar to a surfboard, but is shorter and designed for use in the low water levels close to the shore, as opposed to further out in the ocean where a surfboard is more often used. Just like surfboards, skimboards are manufactured and sold by a variety of sporting equipment companies. If you would like a customized skimboard built to your taste, though, you can make a foam core skimboard yourself.

Things You'll Need

  • Foam
  • Hot knife
  • Fiberglass cloth
  • Masking tape
  • Resin and hardener
  • Paintbrushes
  • Fine grit sandpaper
  • Wax
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Instructions

    • 1

      Get a block of polyurethane foam that is approximately chest-high on the person for whom you are making the foam core skimboard and a few inches wider than the length of the person's arm. The thickness of the foam should be at least 5 inches, allowing you some space for carving the rocker into the foam.

    • 2

      Cut out the board's general shape from the foam with a hot knife. Begin by cutting the corners of the foam so that the foam core resembles an oval with pointed ends. Then, continue to cut the corners and sides of the board down so that the board is a length that is roughly equivalent to the height of the person who will be riding the board from waist to foot and a width roughly equivalent to the length of the person's arm from shoulder to wrist.

    • 3

      Carve out the rocker of the skimboard, depending upon the attributes that you want the board to possess. Carve the foam down to roughly 3 inches thick, keeping the foam straight for a flat rocker, which makes the board fast but difficult to steer. Create an upward curve in the foam, so that both ends curve up and the middle of the board is flat, to help with steering and stability.

    • 4

      Turn the foam so that the top side of the board is facing down. Smooth a piece of fiberglass cloth over the bottom of the foam core. Fold the edges of the cloth over the edges of the board and tape them down on the underside with masking tape.

    • 5

      Combine resin with the included hardener according to the directions provided by the manufacturer. Immediately apply the resin to the foam over the fiberglass cloth with a paintbrush. Carefully brush the resin onto the fiberglass cloth and let the resin set up for 48 hours.

    • 6

      Turn the foam upright and apply fiberglass cloth to the top of the board. Cover the cloth with resin again and allow to dry for two days. Sand the board after the resin is dry to create a rough surface.

    • 7

      Repeat the entire resin process on both sides of the board two more times to get a good, solid coating on the board. Once the final coat dries, Borachi recommends sanding the board lightly with fine grit sandpaper and waxing.