So, I made him one!
The goal was simple; find cheap materials and make a cost effective surfboard. It more than likely will never be used as an actual surfboard, but it very well can be. Well, more like a flotation device I suppose. After all, wood does float right?!
You will need the following:
-Five 2x4 planks (I would recommend more, but that is what I used)
-60, 120, 200, 400, 1000, and 1200 grit sand paper
-Wood Stain (I used gel stain)
-Outdoor Clear Wood/Deck Sealer
-Planer (Electric strongly recommended)
-Work Bench or saw horse
I already had most of the items listed. I used the cheapest 2x4 I could find and I bought the small quart sized cans for the stains. The wood glue was the large gallon, and the wood filler was the larger of the three cans available at Home Depot. Total expense was between $40.00 -$50.00.
I used a lot of advice from this guy, Abe Toke
He has a neat video series I suggest watching before you start! The main difference is he (and most sources I found on the internet) use foam boards.
As a side note, I am going to include a couple of steps I learned from my mistakes throughout this instructable.
Step 1: Got Wood?
The way I did it, the center board had no wedge. The boards to the right and left of the center board each used one wedge. The outer right and left boards each used two wedges. I did this to both the top and bottom of the board. Sorry, I did not take pictures of the bottom side showing the wedges.
The reason behind that is a typical surfboard has a vertical and horizontal curve. Most DIY wooden boards are, well, flat boards. I wanted to make a surfboard, not a wooden plank! Haha. Although I understand flat boards are ideal for mushy/small surf.
Once the glue is set, use wood filler to fill any gaps!! This was my first mistake. I did this later, and it would have been easier and more aesthetically appealing to do it now than later on.
Use a planer to even and curve the board once the glue filler dries. The goal in this step is to simply make the surface continuous. The wedges will make the boards have (for lack of better words) steps. Smooth them out.