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  1. #1
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    Default Shaping and glassing a polyurethane foam fibreglass surfboard

    Finally started work on my favorite hobby. I am on a facebook page for backyard surfboard builders, but find it too intimidating.

    I feel more comfortable on this forum. (I have worked previously as a carpenter)

    My quality and shapes aren't great, but I love the process. They have a face only a mother could love.

    Shaping stand and basic shape rough out.

    shaping stand.jpg step 1.jpg

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  3. #2
    crowie's Avatar
    crowie is online now Life's Good, Enjoy each new day & try to encourage
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    Default

    Looking good

  4. #3
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    Apr 2001
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    Perth
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    Default

    Are you using templates for the profile and rocker lines?

    What tools are you using to shape the foam?

    Are you vacuum bagging?

    Regards from Perth
    Visit www.inthewoodshop.com for tutorials on constructing handtools, handtool reviews, and my trials and tribulations with furniture builds.

  5. #4
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    Default

    Hi Derek,

    I do an outline on one side using a flexible length of material to give me a curve, mostly using my eye and the width and curve that I want/like. I then cut the shape on one side of the blank. Then I used a sheet of cardboard to trace onto, cut the curve in the cardboard sheet and used this to do opposite side of board. With modern blanks the rocker is already inbuilt, unless you have a specific desire for a rocker type. I just use as is.

    It's a board for myself for fun, or if someone likes it. So I'm not bound to a rocker profile.



    Previously I used an electric planer. But this time I am going to try to do the whole board using a surform/s and sanding pad. I want to keep the thickness and using the planer cuts too much foam. A small block plane is required to cut down the wood stringer level, as you sand down the foam.


    I have no experience with vacuum bagging. But it's not required with a polyurethane/fiberglass board.

    Glassing process I use one sheet of 6 ounce cloth on top (for strength) and 4 ounce cloth on the bottom (keeps it lighter). 1 laminating coat and a filler coat and sand finish.

    I have a set of fin plugs, but with this one will use 3 fixed fins this time. ( I have a set I rescued)

    Thanks

  6. #5
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    Default the blank I'm using


  7. #6
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    Torquay
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    Default

    Great stuff.

    You are a class act.

    Many many many years ago when I shaped some boards, I used an electric planer as well, but then also progressed to a surform. Better control of how much you remove.

    Looking forward to your glassing.

    Keep up the great work

    Regards

    Keith

  8. #7
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    Default the journey has begun

    It will be a slow build. patience is a virtue

    1-5.jpg

  9. #8
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    Default rocker

    not roller

    pic 1 is deck up looking nose to tail. pic 2 is deck up looking stern to bow.

    1.jpg2.jpg

  10. #9
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    Default

    Quote Originally Posted by Keith_1 View Post

    Looking forward to your glassing.
    Still a way off yet till glassing stage, but,

    Considering adding (green?) pigment to bottom layer or spraying the blank in an abstract way.

    Adding a pic (stencil or hand drawn) onto the top deck, such as attached, for fun.

    capt.jpg decal.jpg

  11. #10
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    Default ready for 80 grit

    Keeping wood stringer flush is not so easy, need a really sharp block plane, otherwise it tears wood and foam.

    4-5a.jpg 4-5b.jpg

  12. #11
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    Default ordered the fibreglass

    pick up Saturday

    order.png

  13. #12
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    Default almost done (before glassing)

    ready for final sanding

    7-5.jpg

  14. #13
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    Default

    costs for a board made from a 7' blank.

    blank $80

    fibreglass resin cloth and hardener $150

    set of 3 fins including plugs $45

    $275 excluding delivery costs

  15. #14
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    Default still sanding

    I joined and posted on the backyard shapers facebook page also. feeling more confident.
    10-5a.jpg10-5c.jpg

  16. #15
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    Default 4 oz fibreglass cloth trimmed

    bottom ready for lamination resin mix.

    24-5.jpg

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