How to Make a "Bulletproof" Polycarbonate Longboard!

In an incredible epiphany, our team at SPHS decided to make a longboard deck out of polycarbonate!  

Not only is the deck completely see-through, it is also bulletproof!  
*But please, don't quote on us on that.  We are not responsible for any liabilities involving injuries or death regarding the use of the deck as protection equipment.*

But anyway let's get to it!  

Onto the materials!

Step 1: Materials

-3 axis or higher milling machine
-42"x12" sheet of polycarbonate with at least a 3/8" thickness (You may use other dimensions to suit your needs but I don't recommend that you use anything less than the stated thickness.  For a stiffer board, get a greater thickness.)
-MasterCam Program (we used the X5 edition)
-1/4" flat endmill
-1/8" flat endmill
-Sandpaper or sand belt machine
-Griptape
-Common sense

Step 2: Design

For our design, we first sketched it on paper.  

We chose a simple shape, almost in the shape of a bullet, with grooves in the middle of the board on both sides.  

After the sketch, we transferred the drawing to MasterCam.  

We attached the board file as a dwg so please feel free to use it as you wish.  

*We didn't want to sketch anything too difficult, otherwise we wouldn't be able to redraw it in MasterCam.  But if it is within your level, by all means go ahead and get as intricate as you want.*

Step 3: Milling

Before we milled out the board, we did some test runs to see how the polycarbonate would mill.  

At first, we cut it straight through but that was a disaster but we ended up using depth cuts for the milling.  
For the settings, we used a medium cut speed and a high spindle speed.  

*Please experiment with the settings as various thicknesses will alter how the material will cut*

Step 4: Final Product

Take the board to sandpaper to smooth out the edges and apply griptape however needed.

The board turned out VERY flexible but can still be ridden.  We attached a video to show how flexible the board is.  The rider is about 150 pounds.  

Take note that this is more of a novelty than something for actual riding.  You can still ride the board but nothing too intense like downhill bombing can be done.  This board is more for a wow factor.

That's all and thanks for following this tutorial!