Most longboards are made of wood. I wanted something unique so I made mine of aluminum. The aluminum deck is flexible but strong. The entire longboard weighs only 4 kg and is therefore very light!
If you like this design please vote for me in the 'I could make that contest' :)
The idea for the aluminum longboard came from this website: http://bionicgirlnyc.com/2011/03/20/cindrich-aluminum-longboards/
-120 cm of stainless steel bars
-12 aluminum strips of 1 meter (10 strips of 2cm wide and 2 strips of 1,5 cm wide)
-2 pieces of wood
Step 1: Sawing wood to attach the trucks
Copy the holes of the trucks and shape the rest of the wooden pieces as you like. They form the tail and the nose of the deck.
I used multiplex.
Step 2: Attaching the trucks
Attach the trucks to the wooden pieces, by using nuts and bolts.
Step 3: Attaching the aluminum strips the the tail and nose
Attach one aluminum strip to the tail and nose with screws.
Step 4: Bending the strip along the shape of the tail and nose
Bend the aluminum strip and attach it with screws to the tail and nose.
Repeat this step on the the other side.
Step 5: Mounting the middle strips
Cut out two slots on each wooden piece, for the two middle aluminum strips and mount them with glue.
Step 6: Drilling the holes
Drill out three rows of holes.
Step 7: Placing the bars and nuts
Step 8: Placing a horizontal strip
Place a horizontal strip in the middle and secure it with glue.
Step 9: Drilling the holesr
Drill four rows of holes.
Step 10: Placing the bars
Place the four bars and secure them with the nuts.
Step 11: Placing the rest of the strips
Mount at each side one big and one smaller strip.
Step 12: Placing the second horizontal strip
Place a horizontal strip at the bottom of the deck.
Step 13: Mounting the edge strips
Bend two strips around the contour of the longboard at each side and attach them again with screws.
Step 14: Finishing the tail and the nose
Attach a piece of rubber on the tail and nose with glue, so it looks smooth.