Step 2: First lamination

Once you have your mold made, you are ready to start sticking stuff together.

Lay out the materials by taping together a sheet of balsa strips the approximate size of the skateboard mold, maybe a little bigger. On this, place your fiberglass cloth, about the same size. Two layers would be fine.

Mix up some epoxy, probably not more than a few ounces, and work it into the fiberglass until it is all saturated. Then place the balsa sheet on the mold, fiberglass side up, and put the 1/2 foam sheet on top of that. Tape them in place on the mold with a couple of strips of masking tape, then wrap the whole thing with release film, stick it in the vacuum bag, and suck all the air out. You can see how all the layers press together and form to the shape of the mold.

Once it was under vacuum, I placed the mold over a couple of pieces of wood with a heavy weight on the center to create some "camber" in the deck. This isn't necessary for a good board, but I wanted as much resistance to my bulk as possible.

<p>How long did it take you to build? How long does it approximatly take for the epoxy to dry? <br>Awesome by the way! </p>
Google &quot;off road skateboard wheels&quot; <br>
I've been looking for wheels like those for years. Where did you get them?
GOOGLE - &quot;off road skateboard wheels&quot; <br>
What type of wheels are those?
Google &quot;off road skateboard wheels&quot; many online stores and manufacturers will appear.
ohhh man, this is too beautiful dude. you should make a longboard next time you feel like buildin a board, i bet it'd be beautiful too
pretty awesome, is there any way to make the board just as durable, but with thinner layers...how well does carbon fiber work for these projects?
I have no idea about carbon fiber in this proccess, but I do know that carbon fiber can be used to make skateboards(my element fiberlight is a combination of fiberglass, carbon fiber, and wood)
You apply carbon fiber, pretty much the same way as fiberglass... but more expensive.
well not really. They make bikes out of the stuff, and it would be nearly impossible to actually make a board out of it without a giant company backing you. Besides, it wouldn't be able to handle the abuse. Just because they use it in formula one cars doesn't mean it's up to being scraped, bashed, and stood on.
I've personally made 2 boards out of carbon and one with carbon stringers (trying to recreate the Carbon Mummy). From my experience carbon is great in the flex capabilities and is much more resistant to being scraped, bashed, and stood on than any glass board I have made. Like glass, the compression and tensile strengths of carbon are about equal. Carbon is just much stronger in these categories than glass. I have an 'in' on carbon, but if you can afford it, it will make a much stronger/lighter board.<br><br>P.S. I will probably post my first instructable on making one of these boards from scratch including veneers.
Actually, people do make carbon fiber skateboards at home, the process is very similar to this one. Anyone with a vacuum bagging setup and some time to experiment could make a good carbon layup. Thepavedwave has some examples.
i bet it could, but that would be on the expensive end of things.
carbon fiber should definitely work. they use it in F1 cars, some jet airplanes, etc, etc. so, yeah, it should work.
So it's fine to use acetone to clean up?
i love it
Great (instructional, thorough, entertainin'!) ible! And the finished product is a unique deck that you made yourself. Awesome. <br> <br>A note for those who have been discussing making one out of CF or FG, you could do that. It would take many layers, so to keep the expense (weight, do we care?) down, you'd probable want to use a cheaper core. This deck is thick because of the styro-core--which provides very limited strength, but has excellent/light-weight structure for supporting the outer layers, where the overall structural strength comes from (see bird bones and aircraft wing/monocoque design). But it is fathonable, that with vacuum infusion, and with a slow-cure epoxy, one could make the core from something that could bulk up and provide thickness, such as a couple layers of closed cell E. V. A. or even old denim. Then the outer layers could be CF or aramid/kevlar for strength. With enough aramid, you wouldn't even have to worry about truck supports, and it is cheaper that CF. <br> <br>I'll try to get an ible of my own on the subject as soon as the weather permits. I hate to work composites in the cold (heaters, time, etc...)... <br> <br>Using the vacuum and a whole bunch of old jeans (denim is an awesome, dense cotton fiber), I could prob one-off a deck using another deck as a male mold in an afternoon. Check back in may-ish...
That deck looks a bit stiff and thick for my liking... but the instructable is very informative, and very detailed. i like that. :) you can use this for longboards as well I'm assuming? and how would i go about making it a little flexier and thinner? Thank you.
I love boards<a href="http://www.lyrics.uz/">)</a>
Very cool. I'm back in uni and people use these &quot;longboard&quot; skateboards. They look like a lot of fun, but require a great deal of flex between the trucks themselves. They go very fast, and turn lazily. This board looks more like the traditional boards we used to break our bodies with. can it withstand the rigors of life in a skate park?
are the wheels from remote control cars? they look like remote control car wheels LOL
The builder described them as big ol' pimping wheels. I think they're just designed to look like miniature truck tires. Skateboard wheels are subjected to huge forces when a 60 kilo rider lands after a jump. For hobby robots we use RC wheels when weight and traction matter. For really heavy duty service, we use skateboard parts.
LOL they do!
Is good to see someone doing it the way it should be done
This is a great instructable and beautiful work. I especially like your comments in the pictures!
I dont really skate (anymore) but this is so cool. I checked out your blog with the surfboards, and its really awesome. Lots of skilled craftsmanship.
i just googled plaster skateboard mold and came up with this... sick looking board. do you think that a male and female mold made of plaster could take the pressure of being pressed with 2x4's and threaded rod? concrete is just not an option for me at this time... way too heavy.
&nbsp;How about a metal skid plate for making sparks? &nbsp;is that possible?&nbsp;
nom nom tiem?
does it keep its pop cause it looks like a flash not made 4 abuse longboard in the size of a skateboard
wow thats so cool! I might have to try the if I can get the materials
I made a skateboard similar to this in a industrial tech class last year. Except i started with a blank so i just cut and sanded.
Sweet ass ride!! i gotta make one!! where did you get the wheels though? I been looking for those in years...
the only place I have seen them online is <a rel="nofollow" href="http://www.yakresearch.com/a/yakskateboard.html">http://www.yakresearch.com/a/yakskateboard.html</a> They only sell wholesale, though. I may be mistaken, as it has been some time since I did this, but I think I contacted them to ask which retailers they had sold to so I could get just a single set. I do remember that the retailer I got them from only had the one set and wasn't planning on getting any more. <br/>
I was wondering: It seems like a lot of boards don't have the rails described in your instructable. Is it funtional, or more of a "style" thing?
It was functional in the sense that it gave me some material to round over to make the edges curved. Also, the rails connect the top and bottom skins, keeping it from flexing too much. If they were just skins with foam in between, it would be VERY flexy.
OMG! That is flippin' AWESOME!. I HAVE to make one!
<a rel="nofollow" href="http://www.sandwichpanels.org/">Sandwich panels</a>Sandwich panels are used in all types of board sports. For example, a surfboard is a sandwich panel.<br/><br/>That board looks sweet, I am curious what you estimate the deck weighs?<br/>
I just published another instructable on how to make a vacuum pump for less than $20, from an old-fashioned bicycle pump (a $10 &quot;floor pump&quot; from an auto parts store):<br/><br/><a href="http://www.instructables.com/id/EA58LR1F35J1I9N/">http://www.instructables.com/id/EA58LR1F35J1I9N/</a><br/><br/>It pumps faster than the roaraockit pump and gives about the same level of vacuum. (24 inches of mercury, which is 4-6x what a vacuum cleaner can do and more than 3/4 of the way to a perfect vacuum.) You can pump a gallon-jug vacuum reservoir down to 20+ inches in less than a minute.<br/><br/>BTW, here's the link to the 12V tire inflator conversion you mentioned:<br/><br/><a href="http://www.instructables.com/id/E791HNXF23Z39P6/">http://www.instructables.com/id/E791HNXF23Z39P6/</a><br/><br/>For skateboard-sized stuff (and a bit bigger) I think the bike pump is plenty, and you don't need a car charger to run it off of.<br/><br/>
Great links! Lots of folks think the pump is the biggest hurdle to vacuum forming, so anything to break down that entry barrier is great!
shortshift just published a new Instructible on vacuum bagging with the converted bike pump:<br/><br/><a href="http://www.instructables.com/id/Vacuum-bagging-basics./?ALLSTEPS">http://www.instructables.com/id/Vacuum-bagging-basics./?ALLSTEPS</a><br/><br/>
Now that is a great ible. Very nice!
very very very nice instructable. i've always wanted a skateboard. i was going to make an uber-lazyman version and make the deck out of one flat piece of crap wood and make an instructable. but nevermind. i dont think that it'd be worth the time. how much did the entire thing cost?
sound so cool and fun!!! :) wow! nice instruct! wow! (id like to try this, is there another way to do it without the pump?)

About This Instructable




Bio: I'm a Family Nurse Practitioner in both the clinic and the ER. When I'm at home, I build composite sandwich surfboards in my ... More »
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