How To Make A Wood Surfboard
1) You order your kit here picking the size and style you want.
2) The kits are cut from mahogany on a CNC machine (don't you wish you had one!)
3) Your frame kit arrives at your front door in custom package and UPS guy swears at you for the order.
4) The ribs and spar are punched out and the frame is built just like an airplane wing (remember those?)
5) The numbered ribs are slipped into notches in the spar.
6) Ribs and spar are mounted using scrap sticks and a hot melt glue gun (don't sniff the gun bro).
7) The center strip is critical and is the first one installed. The remaining wood strips are added two at a time.
8) Plastic wrapping film (or clamps) is stretched into a string and looped around and under the ribs to hold the planks tight while the glue dries. Or just get your wife to hold them for a few hours while you go surf.
9) Once deck if finished the frame is extremely rigid, the sticks are snapped off and the glue spots removed.
10) Blocks are added at the tail for the fin box and leash cup.
11) The bottom planks are installed and rough balsa planks on the bottom (or whatever you want).
12) The edges are sanded until the deck and bottom are even.
13) The rails are built up in layers using balsa or other light wood.
14) Send it to the glasser or glass it yourself.
15) Crack a beer, you did a great job!