Repeat on the other fins and let cure until hardened. Using some quality masking tape we mask the all the way around the deck of the surfboard about 1-2 inches from the edge of the surfboard. My suggestion is to copy an existing board but my layout will be a typical thruster layout. Reasons for stopping after sanding the hotcoat is if you are concerned with performance and want a light surfboard. The traditional type of surfboards were made with a polyurethane surfboard blank and polyester resin. For use as general purpose insulation for roofing, wall and foundation applications. Once set, sand the overlapping epoxy and feather into the rest of the board. Next it is time to tuck the rails, using the squeegee, wipe off an excess on it and then run the squeegee over the bottom then around the rail and follow it to the deck of the surfboard. These are the materials needed to make the surfboard, I will try not to leave anything out, I also included some affiliate links to them on Amazon: These are the tools I used but not exclusively the only ones that can be used, be creative and find or make your own, I also included some affiliate links to them on Amazon: Note: I want to mention is a word about safety, when working with fiberglass and epoxy. To glue the two pieces together, I used polyurethane glue. Let sit over night. The professional use a powersander/polisher to do the whole board but play it safe and do it by hand. I am sanding the hotcoat, painting the surfboard then gloss coating it. so chances are the average person will not have these anyways. If you are interested in seeing how to power sand watch the video. For each surfboard blank it has a profile for a stringer, I like using these profiles and transposing the numbers to a piece of 3/16" plywood and creating a duplicate stringer. Using some paper I traced out the 1/2 of the surfboard that was just shaped and cut out the paper so I could transpose the shape to the other side of the blank. Use a razor blade and cut the fiberglass where edge of the tape meets the foam towards the bottom of the board. Owens Corning® FOAMULAR® extruded polystyrene (XPS) insulation is a closed-cell, moisture-resistant rigid foam board with excellent long-term stable insulating performance and durability. Sand all the larger surfaces of the bottom and deck, until smooth, take it to a 220 grit if you plan on painting the board. Using ratchet straps tighten them down against the two pieces of wood. To make a stringer there are a few options, trace out an existing board, find a pattern online, draw one in a vector drawing program or my favorite method is to use the Clark Foam catalog. Great job! The last item that I recommend to make is a long sanding block from a piece of wood gluing some super rough sandpaper to it, I like using 20 grit sand paper that is used for flooring sanders. To hotcoat the deck of the surfboard is exactly the same, run a line of tape around the middle of the surfboard but this time let it overlap the epoxy by 1mm. Other tools that can be used are power sanders or a power planer, I don't recommend these as they are very aggressive at removing foam and until you get a feel for working on the surfboard it's better to go slower. 99 HOME DEPOT REMOVES EPS STYROFOAM FROM HOLIDAY PACKAGING October 12, 2017 During the holiday season, as gifts are exchanged and online gifting continues to rise, 25 percent more trash is thrown away—much of it containing expanded polystyrene (EPS) foam packaging, commonly referred to as styrofoam. So an alternative is to make your own surfboard blank* from scratch. To sand the surfboard there are a few methods, you can hand sand it, palm sand it or power sand it with a polisher outfitted with a disc. It has high water resistance and R–value of 5.0 per … I have noticed in the past few weeks the deck has felt very spongy. The trickiest part of shaping a surfboard is the rails. The epoxy will have instructions on amounts, follow them. 24 in. There are plans online to make a hotwire cutting or check out my video where I explain how to make one. There are specially formulated epoxies for making surfboards that have UV protection to keep it from yellowing, I like using Resin Research, I find it the most clear. I skip this step as it adds extra work for minimal value in my opinion. Once all the ridges are sanded out, switch to a finer grit to polish out the marks from the previous grits, I like switching directions between grits so I can see if I sanded out the marks. The first chunk of foam to remove is the outer most lines on the deck. x 4 ft. x 8 ft. R-10 Scored Squared Edge Rigid Foam Board Insulation Sheathing So for this surfboard I will glass it 6oz on the bottom and 6oz + 4oz on the deck. Make sure the edges of the blank where the rail will go are perpendicular to the rest of the surfboard. Visit the Home Depot to buy STYROFOAM Brand SCOREBOARD R-10 2 in. Using a sharp utility knife or razor blade trim off the excess fiberglass around the fin, make sure to leave about 1/8" all the way around the edge of the fin. Could you give a ballpark price for all the materials? But the general idea is tints and pigments are added to the epoxy resin and then laminated into the fiberglass cloth. Once the bottom of the surfboard has cured, it's time to laminate the deck. Use a 3" soft bristle paint brush, coat the bottom of the surfboard, make sure to cover every last bit of surfboard. The amount of resin used is really depends on a few variables: size of the board, weight of the fiberglass, how much the foam absorbs (XPS doesn't absorb resin like ESP does). Remove the foam from the traced out template. These are the materials needed to make the surfboard, I will try not to leave … I bought my foam from Home Depot and it's the pink construction foam with the Pink Panther. When working with epoxy it best to always wear gloves as it can be a skin sensitizer, avoid contact with the skin until it has cured. An easy way to wipe the squeegee clean is to use excess scraps of fiberglass, cut this ahead of time. Where to Get XPS Foam: Pink Foam: also known as foamular. Hope you enjoyed this Instructable and consider subscribing to my here and on youTube, I make various different projects. When you are remove the foam, make sure you are using long even strokes, don't work away at the foam at any one spot for too long, as the surfboard will turn out "wavy" and bumpy. 2 years ago Just as a precaution make sure to test the paint on a surface and make sure that it's waterproof when dry. Using a flexible 1/4" dowel, I weight one end down on the middle of the board and bend to connect the nose at the inner most marks. Squeeze out any excess air bubbles. For the mixing containers, I usually use ice-cream or yogurt containers, so start saving them! This foam is moisture resistant XPS … The fin cant is the angle the fin is tilted outward towards the rails of the surfboard, generally the more cant the more responsive the board will be. Red Foam Board Non Toxic High Grade 20" X 30" Sheets Perfect for School DIY Arts & Craft, Office and Home (Pack of 12) by Emraw 4.8 out of 5 stars 8 $39.99 $ 39 . FOAMULAR C-200 XPS Insulation 24-inch x 96-inch x 1/2-inch Butt Edge FOAMULAR Extruded Polystyrene Rigid Insulation is made in Canada and offers a combination of characteristics that result … The deck is laminated in the exact same fashion but with a few minor differences. of product thickness). Compatible with all other foamboard insulation products, LePage PL 300 is a latex-based adhesive especially designed for bonding polystyrene foam … Once the board is wet sanded to the higher grits, it will still have a dull look to it. Do this will all the measurements. Local store prices may vary from those displayed. Let harden for 24 hours. The surfboard should really start to pop at this step. It would be nice to know this information. When removing the foam, make sure to use long even passes, don't scrub at any one spot as you will end up with a uneven and bumpy surfboard. Give it some time to soak in the cloth. Since XPS foam is closed cell foam, it doesn't like having glue stuck to it, which presents a minor challenge when fiberglassing. It's great for above or below grade applications and easy to cut with a … © 2000-2020 Home Depot Product Authority, LLC. Mix up the epoxy and since there is an extra layer of fiberglass, the deck will require more epoxy resin. Question Overview Model # 270129 Store SKU # 1000155116 FOAMULAR Extruded Polystyrene Rigid Insulation is made in Canada and offers a combination of characteristics that result in long-term thermal … Awesome job, thanks. My tool of choice for foiling the fins is a angle grinder with a flap disc. Cut this ahead of time hotcoating and is just starting to harden, ( 2-3,. When you run the squeegee clean is to look at the stringer certain Terms of use automotive coats. Add thermal Insulation to attic and crawl space access panels and pet houses saved $. 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