How to Make Surfboard Blanks

Surfboard blanks, the core material of surfboards, have to be tough, sturdy and water resistant with a high amount of buoyancy to keep the board afloat. Polyurethane foam makes a good starter material for building your surfboard blank because it allows for easy shaping and is lightweight enough to permit fast speeds on the waves. Locate a polyurethane distributor and look into shipping costs, or avoid these charges entirely by finding a polyurethane manufacturer in your area and picking up the materials yourself.

Things You'll Need

  • Polyurethane foam board
  • Permanent marker
  • Hand saw
  • Electric planer
  • Drill sander
  • Sandpaper
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Instructions

    • 1

      Make a template for your surfboard blank on a piece of paper, drawing to scale. Familiarize yourself with the multiple dimensions, including the length, width (the measurement from one side of the board to the the other at its widest point), thickness (the measurement between the underside and the topside of the board) and rocker (the measurement of the curve from the nose to the tail of the board.

    • 2

      Draw the outline of your blank on the large piece of polyurethane foam with permanent marker. The dimensions of the board will depend on your weight, surfing ability and personal preference. Keep in mind that the thicker the board, the more buoyant it will be.

    • 3

      Cut out the shape and dimensions of your surfboard with a hand saw. Shape the nose and tail of the blank with a drill sander. The middle of the surfboard blank should be the widest portion of the board, and the nose and tail should taper in.

    • 4

      Use an electric planer to smooth the surface of the cut-out blank. Smooth the blank further and flatten any imperfections using sandpaper.