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27th April 2021, 01:04 PM #1
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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27th April 2021, 02:35 PM #2
Looking good
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27th April 2021, 04:49 PM #3
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 PerthVisit www.inthewoodshop.com for tutorials on constructing handtools, handtool reviews, and my trials and tribulations with furniture builds.
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27th April 2021, 09:32 PM #4
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
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27th April 2021, 10:05 PM #5
the blank I'm using
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28th April 2021, 10:29 AM #6GOLD MEMBER
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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
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1st May 2021, 01:34 PM #7
the journey has begun
It will be a slow build. patience is a virtue
1-5.jpg
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1st May 2021, 10:04 PM #8
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3rd May 2021, 09:22 PM #9
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4th May 2021, 02:16 PM #10
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6th May 2021, 12:45 AM #11
ordered the fibreglass
pick up Saturday
order.png
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7th May 2021, 02:39 PM #12
almost done (before glassing)
ready for final sanding
7-5.jpg
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8th May 2021, 02:23 PM #13
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
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10th May 2021, 07:52 PM #14
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24th May 2021, 04:26 PM #15
4 oz fibreglass cloth trimmed
bottom ready for lamination resin mix.
24-5.jpg
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