Building your surfboard is a science, but not rocket science. 

LEARN by watching videos.  MAP out a game-plan -- building a board can be broken down to x3 phases: Shaping, Laminating, and Finishing. SET UP your space.  PURCHASE the right building materials. 

GO FOR IT!

Picking the Right Foam Surfboard Blank... 

Modern surfboard blanks are made from two types of foam: polyurethane (PU) and polystyrene (EPS).

POLY or PU (Polyurethane) Blanks:

• • Construction: Made from a polyurethane foam core, typically with polyester resin, although epoxy can also be used. 
  • Weight: Heavier than EPS blanks. 
  • Feel: Tend to sit lower in the water, providing a more stable ride, especially in hollow waves. 
  • Durability: More susceptible to dings and heel dents than EPS, and polyester resin can yellow and deteriorate over time. 
  • Flex: Typically more flexible than EPS, offering a softer feel and carving ability. 
  • Cost: Generally more affordable than EPS. 

EPS (Expanded Polystyrene) Blanks:

• • Construction: Made from a closed-cell foam core, usually with epoxy resin (cannot be used with polyester resin). 
  • Weight: Lighter than POLY blanks. 
  • Feel: More buoyant and float higher on the water, making them easier to paddle and potentially more sensitive for progressive surfing. 
  • Durability: Stronger and more durable than POLY, with less risk of absorbing water if dinged. 
  • Flex: Tends to be stiffer and more rigid than POLY, potentially leading to a chattery feel underfoot in certain conditions. 
  • Cost: Generally more expensive than PU. 
  • Environmental Impact: More environmentally friendly due to the potential for recycling and reduced production of toxic chemicals. 

Key Differences Summarized:

IMPORTANT SUMMARY: EPS Foam must be fiberglassed with Epoxy Resin. Polyurethane Foam can be fiberglassed with either epoxy resin or polyester resin. Most boards are made of polyurethane foam blanks using Polyester resin. When repairing your board, it’s essential to use the correct resin, as failing to do so can exacerbate damage. For example, DON'T repair epoxy boards with polyester resin -- this will cause the foam to melt. However, YOU MAY repair a Polyester board with Epoxy Resin. 

x3 Phases of Board Building... 

1 - Shaping 

A rough surfboard blank, either polyurethane (PU) or polystyrene (EPS), is shaped using specific templates and shaping tools. CLICK HERE for free templates from ishaper

A list of shaping tools includes: 

• • a Sureform 
  • a Stringer Planer
  • Sanding Screen
  • Recommended: an electric planer

2 - Laminating

After a foam blank is shaped, it’s laminated. This process combines both resin and fiberglass cloth to seal the foam and create strength. Most modern surfboards are laminated with four- and six-ounce fiberglass cloth using laminating resin (polyester resin without the addition of sanding solution) or epoxy resin.

First, the cloth is cut to size and laid over the foam. Then resin is applied with a squeegee to evenly distribute and saturate the resin in the cloth. The process should be repeated on the bottom, carefully wrapping the rails to blend over each other. This is standard procedure for both polyester and epoxy resin using fiberglass cloth.

3 - Finishing

Once the board is laminated and the fin boxes are put in, it’s time for finishing. This refers to how the surface of the board appears. There are two basic finishes: sanded or gloss. Both begin with a final coat of resin for finish sanding. Polyester boards require sanding resin, which contains a liquid wax additive that coats the surface for easy sanding. (*Note:* Laminating resin should never be used for finishing; the surface will remain tacky.) Epoxy resin is used for both laminating and finishing.

The final coat of resin must be sanded, usually with a foam-backed sanding wheel and a medium-grit sandpaper. This step evens the surface of the board. A sanded gloss coat is the base for either a sanded or polish finish. Sanded finishes are then wet-sanded with a fine grit and sprayed with lacquer. Gloss finishes require additional wet-sanding and polishing.

The Surf Source has all of the tools and materials you need to build your Watercraft.

→ CLICK HERE for a listed GUIDE ON HOW TO MAKE A SURFBOARD IN 39 STEPS