Foam Core Kiteboard

Step 3 Cut the foam

Cut along the lines you've traced out onto the foam. Fiberglass cannot be layed around a 90degree edge. Use a power sander or a knife to round down the edges of the upper layer of foam so that they meet the lower layer and the glass will not have to round any sharp corners.

For the lower layer of foam one could leave the edges flat and simply lay the glass to the edge of the board and not around it. I chose to shave the foam to a sharp edge (this could come back to haunt me) and have the top and bottom layers of glass meet.

I found shaving off the core-cell foam with the knife to be the most effective means. Remember to always cut away from yourself! Sanding this foam down will take a long time but it works well for finishing the knife-cut surfaces.