I decided that I needed a surfboard to keep at the office for the lunch time surfs and not beign able to afford anouther board figured that I'd make my own. It's a 6'10" x 20 5/8" x 2 5/8" with a Surfblanks Australia Blue foam PU blank laminated with SP 115 Epoxy Resin.



Edit: Shaping the blank - I cheated! There's a company in Mona Vale that has shaping machines and they shape the blanks for a couple of companies on the northern beaches (Sydney) so I bought the blank and took it to them and the above picture is what you get form them. It takes about 20min of light hand sanding to finish the blank. To design your blank you use a Shaping program on your computer send them the file and drop of the blank.

If your interested http://aps3000.com/ has the shaping software and they also sell shaping machines so you can see how they work.



I've laminated the bottom skin (1 layer of RE165 with RE400 patches iwo the fin locations)

I'm hoping to laminate the top skins tonight.

Yeah sorry bout the slow postings for the next stages I've missed a couple of them.

I laminate the top skins last week, this was 2 layers of RE165 (full coverage, 1st skin laped down to the edge of the rail and the second lapped 1"-2" onto the bottom of the board, after the laminate cured I did two fill coats of resin (this week)


(deck skins laminated with fill coats, you can see the fin plug locations where the FCS stickers go)

Mid this week I flipped the board over and did two fill coats on the bottom on



And today I put the fin plugs in - those nice fin patches you saw in the top picture - yeah there in the wrong spot (so bitter)



Now it's going to sit in the water heater closet for a post cure before I sand it. After sanding I'm going to put a polyurethane coating on it (spray bomb) and call it done

Material -

?7'1" Foam blank for a 6'10" board
?9.5lm of RE165 (roll width is about 1000mm)
?1.5kg of Epoxy resin with a 3:1 hardener ratio (note - measuring epoxy mix ratios by weight is more accurate than volume as they say the scale doesn't lie) so in total I used 2kg of resin
?1 set of fin plugs
?1 leash plug
?1 set of g-am fins

If your keen to make you own boards check out www.surfersteve.com/cgi-sys/suspendedpage.cgi (you can learn Spanish at the same time). It a pretty good guide to follow.

There's tons of videos on you tube as well showing people laminating surfboards.

More piks crazy howz it goin?

Yeah I haven't finished it yet I've had issues trying to find the time to sand it between work, sailing, study, and everything else.

I've hit it with a sander




But it still needs a bit of work I went at it with a 8" buffer/sander/grinder with 60 and 80 grit sand paper. It's amazing how much resin you can get on the board with the hot coats, thought I had already put a dent in it some how it turned out to be a resin pool . You can see the dark rings on the deck where the fun plugs are they give you stickers for that and it should be a thinner circle but I decided not to shell out the $150 for the FCS install tools

I'm hoping to have it done this weekend and sprayed with a clear PU finish

All up it didn't cost me much the whole thing would propbably cost your average guy $350-400 or so depending on materials you buy