How to Build an Old Wooden Surfboard

Making an old-fashioned surfboard harkens back to the days of early surfing, when big, long, wooden surfboards were common. The process involves a complicated number of steps with tools, so patience is a critical requisite for such a project. Once you have all the necessary materials, the process will require a good workspace and lots of time, so don’t rush. However, when you’re finished, you’re likely going to enjoy the completed surfboard, given that it’s your own handy work.

Things You'll Need

  • Beams of balsa wood
  • Power saw or table saw
  • Wood carving tools
  • Palm sander
  • Paint brush
  • Industrial wood glue
  • Wood clamps
  • Wood planer tool
  • Fiberglass resin
  • Hardener
  • Bucket
  • Mixing stick
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Instructions

    • 1

      Order a lot of balsa wood beams longer than the length of the surfboard you plan to make. Pick out the wood beams that are similar in color and grain pattern.

    • 2

      Draw out a template of how the surfboard should be shaped. Use a power saw or table saw to cut the wood beams to match the template. Cut each piece to match a specific section of the surfboard on the template.

    • 3

      Sand and plane each wood piece until it is formed into the shape of the board desired. Use wood carving tools and a palm sander to work the wood until you are satisfied with each beam and placement.

    • 4

      Use a paint brush to apply industrial wood to the side of each carved beam. Apply the glue two beams at a time. Paint the glue on, then press the beams together. Clamp them and let the adhesive cure for a few hours. Glue the beams in pairs while waiting for the first set to dry. Keep clamping each set.

    • 5

      Take the pairs of beams — now glued and dried — and begin to glue them together. Complete the board blank when all the pairs of beams are glued into one assembly. Clamp the entire assembly together with various wood clamps to keep the new glue in place. Wait for the assembly to adhere and dry out.

    • 6

      Continue sanding and shaping the now-assembled blank with a wood planer and the palm sander. Work the wood smooth until it feels like one solid shape from beam to beam, without separation or edges. Continue shaping until the board matches your template.

    • 7

      Use a wood saw to cut out a tail-fin blank for your board. Take the fin blank and work the edges with a sander until they are rounded. Keep sanding the blank until it forms the fin shape you want. Cut the base end of the fin with a clean saw cut so that it’s flat. Finish it off with a sander and glue it to the bottom of your board.

    • 8

      Mix fiberglass resin and hardener in a bucket with a mixing stick. Paint the entire board and tail-fin with the fiberglass resin. Continue the process until the board is thoroughly painted with resin, including all seams and joint areas. Apply the resin until it cures about a quarter-inch thick. Let the resin dry.

    • 9

      Sand the cured fiberglass resin down so the board has a smooth surface. Smooth out the sanded area and keep sanding until the resin surface has no aberrations, bumps or lumps. Do the same for the entire board until finished. Wash the board off with running water and let it dry. Examine your finished product and use as desired.