Surfers nowadays are mostly accustomed to foam or fiberglass boards. Well, there’s no denying that these lightweight surfboards provide great convenience when it comes to riding the waves.
But, more and more surfers are promoting the use of hollow wooden surfboards. These boards are more buoyant, gravity-efficient, fashionable, and environment-friendly than conventional surfboards on the market.
Are you interested to try building and using your own hollow wooden surfboard? It’s easily done with the use of woodworking plans. Let this general guide show you how it’s done.
Materials Needed:
Paulownia wood
Plywood boards
Super glue
Epoxy
Fiberglass
Procedure:
1. Select a surfboard design from a woodworking plan or create your own using a computer software such as AKU. The designs typically consist of a surfboard top, bottom, rails, and the inner support framework that give the board its hollow structure and resembles a fish skeleton. Ensure you have a print-out of the design to act as template for the entire surfboard.
2. Glue together two pieces of Paulownia wood boards. Lay the surfboard base and bottom shape on the glued boards. Trace and cut the board accordingly.
3. Take the plywood boards, then lay and secure the template for the board’s inner support framework. Use a CNS router to cut the inner support framework pieces precisely from the plywood.
4. Take out the pieces carefully from the plywood using a pulse saw. Then, smooth the edges of the pieces with a block sander.
5. Do a dry fit for the framework by piecing them together first sans the glue. When everything fits nicely in the dry fit, start creating the permanent framework by carefully gluing the spine and ribs together using a strong super glue. Let the finished framework dry completely.
6. Place the framework on the surfboard’s bottom part. Position it well and clamp down on the board so it doesn’t move.
7. Carefully trace the lines of the frame with a pencil onto the surfboard’s skin. Measure and mark a set distance from each rib end as well.
8. Remove the clamps and set the frame aside for a while.
9. Squeeze epoxy over the network of lines you’ve traced on the board’s skin earlier. Reposition the frame over the skin exactly as you have done previously. Clamp the frame to the board skin and leave overnight to secure.
10. Create the surfboard’s side (rails) by taking 12 pieces of thin wood strips glued and clamped together layer by layer according to the design.
11. Attach the rails to the board using epoxy. Add the top skin of the board to the frame with epoxy. Leave to secure overnight.
12. Trim off any excess board skin. You may use the board’s rails as a guide in trimming. Round the surfboard’s top edges using a wood plane. Shape the board’s tail and nose with a saw rasp. Afterwards, smooth the entire board using a sanding block.
13. Coat the finished surfboard with fiberglass and epoxy as a final touch.
As you can see, learning how to build a wooden timber hollow surfboard from woodworking plans is easy. Even if you aren’t that well versed with the craft, you’ll soon have a board ready for use as long as you follow the steps carefully.
Give your typical fiberglass and foam surfboards a break. Catch some waves with your sturdy and beautiful DIY hollow timber surfboard today!
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