2 x 4 lumber (for the jig)
Cheap 1/8" plywood/ particle board (for the jig)
1/8" sheets of fine woods (for the board) - I used 4 [2' x 4'] sheets of 1/8" birch and 1 [2' x 4'] sheets of 1/8" mahogany for the centre of my board.
Marine Epoxy (Comes in 2 chemical parts you mix together then apply) - I have a picture of my epoxy before we started using it
Paint (I used metallic car paint, got a sample from an auto body shop)
Grip Tape (available at most board shops, anywhere they sell skateboards, West 49 etc)..
Wakeboard Fins (I used Ronix fins)
Step 1: Cut Out Rocker
Draw the rocker shape onto 2 [2 x 4]'s that are 4 feet long, then cut along the line.
I hammered a few nails into the 2 x 4's *away from the cut line* and cut them both with one pass on the bandsaw
KEEP BOTH HALVES OF THE 2 x 4 YOU CUT, YOU NEED BOTH
You will end up with 2 'negative' pieces and 2 'positive' pieces.
I decided to make my board mimic the rocker of the Liquid Force 2008 Faction because that is what I had ridden before. So for me, it was easy to trace the rocker straight from the board then cut it out. You can design any rocker shape you want
Step 2: Jig Spacers
Step 3: Finish Jig
(So when you put the top and bottom together the boards are touching)
*The second photo has the jig pieces on the left
Then the Jig is done and you are ready to form the board.
Step 4: Laminate Boards
Use marine epoxy to laminate the wood sheets to one another. It comes in a part A and B; mix these together in equal parts and apply between all 5 sheets. Make sure to spread a thin coat completely over each board. If it is too thick it will just ooze out the sizes when you clamp it.
I used 5' clamps because that's all I had available to me. I'm sure it's overkill; you would not need clamps as large as these but you want to make sure you have lots of even pressure on your jig. Leave the epoxy to dry for longer than it says on the instructions because you want it to be completely solid when you do the next steps.
*EPOXY IS TOXIC. Make sure to use gloves and a mask and follow all the safety instructions!
After you are happy with the board's shape, use a jig saw to cut out your board. Try to keep your cut perpendicular to the surface of the wood.
This part is really hard because of the board's rocker shape, and it is easier to use the router on the convex side of the board and then sand the edges on the other side down with a palm sander. It won't be to the same curvature, but it will still look nice.
BEFORE you start painting, decide on what fins you want on your board [if you want any] so you can drill the holes before you start sealing the wood.
Step 7: Varathane
Step 8: Painting
I wanted the wood to show through so i did a simple design. You can easily paint the whole back if you want too
If I could do this project again I would love to try out some wicked graphics.
Step 9: Final Layer
Sticking it down isn't particularly easy - its very sticky stuff, you get one shot
To trim the edges of the tape, take a rasp and file around the edges. Finish it up with sandpaper and more Varathane applied with a paintbrush between the strips of grip tape.
Step 11: Ready to Ride
Then the board is ready to ride!