Instructables
Picture of Hollow wooden kitesurfboard
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This is how to make a hollow wooden kiteboard from marine plywood. The design and construction of this board has been simplified as much as possible to facilitate quick, cheap construction with out specialised tools.

The board consists of three layers of wood laminated together to form the core of the board. The centre lamination is not solid in order to reduce the weight of the board without compromising the strength too much.

This style of board is known as a directional , it is designed to be ridden in one direction only and must be gybed or tacked similar to a windsurf board in order to go in the opposite direction. This requires practice and is not best suited to a beginner. The benefits of this style of board is that it does not require any design compromises, you can have huge fin area at one end (for pointing up wind and loading up for jump)s and plenty of nose rocker in the other end for riding in choppy or surf conditions.


 
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Step 1: Acquire your tools and materials

Picture of Acquire your tools and materials

Materials required:

1 8' x 4' sheet of 6mm thick marine plywood

250ml of epoxy resin

4 x stainless steel self tapping screw for attaching footstraps

4 x stainless steel washers

4 x Future Fins Fin boxes (side type)

4 x Future fins

2 x Footstraps

Notes:

Marine plywood is preferred but good external construction plywood will work fine

Epoxy resin is used to join the laminations together as well as seal the board from the elements as an alternative the laminations may be glued with water proof polyurethane glue as this is easier to use (1 part) and the ply can be sealed with varnish once the board is finished instead

Future fins are preferred over FCS as they are stronger and easier to install correctly

Footstraps any hard ware is optional as the board may be waxed and ridden like a surfboard instead.

Tools required:

Handsaw

Block plane

Rasp

Sand Paper

Drill

3mm Drill bit

12mm Drill bit

Measuring tape

Notes:

A handsaw is better for cutting plywood than a powered saw as it tends to cut a smoother less wandering line and does not splinter the wood as much.

vlassadar7 months ago

Hi, this is it! The method I'll be using as a guide for my surfboard! Would you mind sharing an opinion on the plywood thickness - it seems too strong to me like this, I intend to use 3 solid layers of 4 mm birch plywood - it's relatively hard material. I have also available a good quality poplar plywood, which seems to be softer and weaker, but lighter.

Also, i intend going with the PU and the varnish, if the strength of the board will be enough like this. The epoxy seems as the more tested way to go, but seems harder to use.

fjordfiend (author)  vlassadar7 months ago
Thinner plywood would work great, after riding this board for a while now I'm regretting not lightening the center lamination a bit and using thinner ply top and bottom.
emway2c9 months ago
I know this is VERY unesisary but:
surfboard surfboard. You know the rest
Xenophon9 months ago

Excellent project. You should consider entering this into the Woodworking contest.

wilgubeast9 months ago

Truly a project that honors the origins of Instructables: sharing kiteboard designs. Check out the founder's description of the launch of Instructables.