How to Make a Styrofoam Surf Board

Surfing is a favorite past time for those residing in coastal cities. Many types of surfboards exist, including those made of styrofoam, or polystyrene. Styrofoam surfboards may have some benefits over others. Combined with epoxy, styrofoam surfboards are hard to damage. They are cheaper, lighter in weight, float better and more environment friendly compared to resin surfboards. With the correct materials, you can make your own cost efficient styrofoam surfboard.

Things You'll Need

  • Styrofoam surfboard blank
  • Hand saw
  • Electric planer
  • Spackling
  • Sandpaper
  • 4 oz. woven fiberglass cloth
  • Squeegee
  • Epoxy
  • Foam paint brush
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Instructions

    • 1

      Shape the surfboard blank to your desired look using a hand saw. Remove the outer layer of styrofoam using an electric planer on all sides of the surfboard blank. Finish by smoothing with sandpaper.

    • 2

      Spread lightweight interior/exterior spackling over the entire surface of the surfboard blank with a squeegee. Since epoxy is expensive and absorbs into the styrofoam, it is cheaper to seal the surfboard blank with spackling first. Sand the board with sandpaper.

    • 3

      Cut the 4 oz. woven fiberglass cloth (or 6 oz. for long boards) to the shape of the board. Two layers should be cut for the top of the surfboard and one layer for the bottom. Place the cloth on the surfboard. Using your squeegee, apply a coat of epoxy to the fiberglass cloth and surfboard blank. Allow the epoxy to dry for approximately 6 hours. Repeat this process until the whole board is laminated.

    • 4

      Apply another coat of epoxy using a foam paint brush. The second layer is used to fill in any gaps and to smooth out rougher surfaces. Cover the entire surface of the surfboard.

    • 5

      Sand the entire surface of the surfboard with sandpaper once the epoxy has dried. Paint the surface with a water-based acrylic paint if you desire. Add artwork using computer-printed images on rice paper. Apply the rice paper to the surfboard using epoxy and your squeegee.

    • 6

      Apply the glossy coat of epoxy to the surfboard using your foam paint brush. Allow the top coat to dry. To add traction to the top surface of the board and prevent slippage, lightly sand the surfboard with sandpaper.