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.
Step 1: Acquire your tools and materials
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
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.
3mm Drill bit
12mm Drill bit
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.