How to Create a Wakeboard

Manufacture a mold for your wakeboard from metal or wood.

Shoot foam core into the mold as you create a wakeboard. A rim machine that creates shoots foam cores will work well for this process.

Heat the molds, then fill them with the required foam core. In six or seven minutes, the core will be ready to take out of the mold.

Finish the foam core by going around the edges to knock off any excess foam. Examine the rest of the board and fill in any holes as you create a wakeboard. Once it is ready, you can allow it to proceed to the next step.

Place the foam core into the sandblasting machine (that actually shoots metal shavings) and create the texture for your wakeboard. By adding the texture to the wakeboard, you allow the resin to adhere far better.

Lay out the sheets of fiberglass you will need when you create a wakeboard and cut the pattern you require to cover the wakeboard.

Add graphics to the paper then transfer them to the PVT which will cover the wakeboard you are creating. Pin the PVT top in place so that the mold will adhere it to the wakeboard in the proper place. Pre-form the sheet so it will not have any wrinkles when you adhere it to the wakeboard. Laminate the graphics with the various materials used for the wakeboards and press them together with heat, thus laminating them as you create a wakeboard.

Place the foam core and all the different layers together (see the above steps) into the mold and press them together while heating them as you create a wakeboard. Wet the foam cores on the top and bottom, then lay on the various layers. Heat the mold for about nine minutes or so, then remove the wakeboard from the mold and cut off any excess with files.