How to Build a Sailboard

The sailboard is another name for a windsurfing board, onto which the mast and sail are attached and the windsurfer stands on the board while riding. Design aside, sailboards can be expensive to buy from commercial manufacturers, so building your own less expensive version is ideal if you have the knowledge. The most common type of homemade designs include shorter speed boards that require only one piece for the board, unlike longer beginner boards that have a centerboard inserted into them. Shorter boards are usually made to a maximum length of 114 inches and made from a Styrofoam block.

Things You'll Need

  • Styrofoam block
  • Car battery
  • Resin
  • Glass cloth
  • Mast track
  • Fin box
  • Nichrome hot wire cutter
  • Sandpaper
  • Plywood blocks
  • Table saw
  • Nails
  • Hammer
  • Brush
  • Pencil
  • Paper
  • Tape measure
  • Plywood
  • Knife
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Instructions

    • 1

      Draw a detailed plan of the proposed sailboard design, transfer the design as side pieces and a top/bottom template. Cut the templates out of the plywood and attach the side templates to the foam block securely with nails.

    • 2

      Cut the Styrofoam block to shape using a nichrome hot wire cutter attached to a car battery for power. Remove the side templates and attach the top template and again cut out the shape of the board with the nichrome hot wire cutter.

    • 3

      Sand the board for smoothness using sandpaper attached to long plywood blocks. Heat a knife and cut the openings for the mast track and fin box, insert these accessories after the holes are cut.

    • 4

      Place the glass cloth over the bottom of the sailboard blank, usually two layers of glass cloth are applied to the bottom of the board. Brush resin over the top of the glass cloth to seal the board. Allow the resin to dry before repeating the process for the top of the board, applying three layers of glass cloth.

    • 5

      Apply a final coat of resin as a finish coat. Sprinkle sugar or coarse salt onto the surface when the resin is partially dried to create a non-slip surface. Allow it to dry.