How to Shape Your Own Surfboards

Shaping a surfboard is a challenging project and is not for everyone. If you like to surf and have wanted to shape your own board, it can be a really rewarding project. This project will require power tools and some technical know-how. It is a good idea to have in mind the general shape of the board you wish to build. You can purchase premade templates for the design you wish to build.

Things You'll Need

  • Jigsaw
  • Sawhorses
  • Planer
  • Electric sander
  • Sand paper
  • Sanding block
  • Tape measure
  • Pencils
  • Rubber squeegee
  • Paint brushes
  • Latex gloves
  • Filtering mask
  • Locking clamps
  • Electric drill
  • Foam blank
  • Resin and catalyst
  • Hot coast resin
  • Think sheet of plywood
  • Leash plug kit
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Instructions

    • 1

      Design a template for your surfboard or buy a predesigned one. Pattern your design after surfboards you have used. Consider nose and tail design, rail shape, width and length when designing your surfboard.

    • 2

      Trace your template onto a thin sheet of plywood and cut it out using a jigsaw. Clamp the plywood in place before cutting your pattern.

    • 3

      Transfer the pattern to top and bottom of the blank foam core. Make sure to purchase a core that is has the proper foam density to support your body weight.

    • 4

      Cut the basic shape of the surfboard from the blank using a jigsaw.

    • 5

      Shape the board with an electric planer. Shave thin layers of foam off the blank until you get the shape you want. Shape the nose, rails and tail and deck and bottom of the blank to the desired density. On the nose and tail, you may have to use a hand planer to get the shape you require.

    • 6

      Turn your board over so the bottom side is up and clamp it to the workhorse. Roll a fiberglass sheet over the bottom, make sure that you have excess fiberglass sheet hanging over the edge of the rails.

    • 7

      Mix the resin and catalyst. Pour the mix onto the board starting at the center. Spread the resin over the board with a rubber squeegee. Fold the excess fiberglass over the rails as you use the resin. Let the resin set overnight and repeat on the deck side.

    • 8

      Install the fin kit to the bottom of the board.

    • 9

      Apply a coat of hot resin to the bottom of the board. Let dry as required and repeat on the deck.

    • 10

      Drill a hole in the bottom of the board. Remove any excess foam and pour some resin mix into the hole. Insert the leash plug kit into the hole and cover with resin and let thoroughly dry.

    • 11

      Check that the board is dust free, then wet down the board. Using an electric sander and wet-dry sandpaper, sand the board to a smooth finish.