The price of boards seems to have skyrocketed here in Canada over the last season. Why buy what you can easily make? This is a great beginner fiberglass project that allows for tons of creativity and fun.
Step 1: Materials and Tools
- 3/8 in 4ft x 4ft Core-cell or Dyvini-cell foam. $40 CAD
These can be found at marine supply stores and generally come in 4ft x 8ft sheets. Look for appropriately sized 'scraps' to save money. I found the core-cell to be extremely durable and resistant to dings while building.
- 3m x 1.5m of 6 ounce bidirectional fiberglass. $22 CAD
This should be enough to put 3 layers of glass on the top and bottom of the board.
- 30cm x 50cm uni-directional carbon fiber. $9 CAD
This will provide added support under the foot straps.
-1.25L of Marine Epoxy. $55CAD
West Systems 105 and 205 Resin and Hardener worked very well for me. The pumps made measuring the correct ratio of Resin to Hardener a breeze and allowed me to work with smaller amounts of epoxy at once.
-Glass micro bubbles. Commonly referred to as 'Micro'. These are mixed into the epoxy as filler and result in lighter weight. Use a mask so you don't inhale.
-Hardware $10 CAD
-Stainless threaded inserts for the foot straps and grab handle
-Stainless Screws for the foot straps, handle and fins.
-finishing washers for the fins
-Fins and Footstraps
This is where things can get expensive. Foot straps are easy to build. See some of the other great instructables for more information on making your own. I found old Dakine ones for 30$. One can probably get away without fins. Fiberglass kite fins sell for roughly $150 CAD, I found plastic ones for $50 CAD. There is also the possibility of shaping fins into the foam as you see on some wakeboards.
A one or two part polyurethane should do the trick. Forget about spray paint.
-Old credit card type plastic card for spreading epoxy.