How to Apply Fiberglass to a Surfboard

Many avid surfers enjoy making their own surfboards. Polyurethane surfboard blanks are available in an incredible variety of shapes, sized and weights. These blanks can be carved and modified to meet the exact needs of a surfer. Once the blank has been chosen, the next step is to apply fiberglass to produce a finished surfboard.

Things You'll Need

  • Surfboard blank
  • Sawhorses
  • Roll of fiberglass cloth
  • Scissors
  • Straight pins (optional)
  • Epoxy resin and catalyst
  • Disposable buckets
  • Mixing sticks
  • 4-inch plastic squeegee
  • Electric sander
  • Rubber gloves, dust mask, goggles, protective clothing
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Instructions

    • 1

      Set the surfboard blank upside-down on a pair of sawhorses.

    • 2

      Roll fiberglass cloth onto the blank. Trim the cloth so that one inch hangs off of the ends of the blank on all sides. If needed, hold the cloth in place with straight pins (making sure they can be removed easily).

    • 3

      Cut slits in the fiberglass cloth overlap at the nose and rear corners. These areas may not lie flat otherwise. You can overlap the sides of the slits if needed.

    • 4

      Mix a batch of epoxy resin with its catalyst in a disposable bucket. The exact mix ratio will be listed on the resin container. If you don't know how much resin to use, it is best to err on the side of too much. Be sure to stir the resin and catalyst completely, scraping the sides and bottom of the bucket. If it is not thoroughly mixed, there will be gummy areas of half-cured resin on the surfboard.

    • 5

      Pour most of the resin onto the center of the blank, being careful not to allow any overflow to drip off of the board.

    • 6

      Use a squeegee, held at a 45-degree angle, to work the resin into the fiberglass. Start in the center and work outward, so that the resin will be evenly distributed and air bubbles will be forced out. Air bubbles greatly weaken the finished surfboard, so be sure not to leave any behind. If you used pins to hold the fiberglass in place, remove them as you work.

    • 7

      Fold the excess fiberglass over the edges of the blank and paste them to the underside of the blank with resin. Be sure to eliminate any drips, or you will have a lot more sanding to do later.

    • 8

      Use the remaining resin in the bucket to fill in any gaps or thin areas.

    • 9

      Allow the resin to fully cure until is has hardened.

    • 10

      Turn the surfboard over on the sawhorses.

    • 11

      Apply fiberglass to the other side of the blank, following the same procedure as on the first side.

    • 12

      Allow the fiberglass to cure.

    • 13

      Sand both sides of the board smooth, paying special attention to the seam where the two layers of fiberglass overlap.

    • 14

      Add paint and removable fins to finish the surfboard.