Step 1: Design Your Board
In this files section are two CAD files (DXF and Corel Draw) of my favorite board.
I printed my design out on a large format printer. You can also just draw your design my hand on a large sheet of paper.
Step 2: Cut Board
Rough cut the shape with a table saw or jig saw, and then smooth the edges with a belt sander. Round any sharp edges so the board doesn't cut you, but also so it's not prone to knicks and dents that will allow water through the epoxy.
Make sure you align the grain of the wood on the face of the plywood along the direction of the board.
Drill holes and install 1/4-20 tee-nuts for mounting footstraps and a leash attachment point.
Step 3: Board Size
Step 4: Install T-nuts
Step 5: Print Graphic
Step 6: Lay Up Fiberglass
Step 7: Epoxy Board and Apply Graphic
Printout your graphic on plain white paper. Once soaked with epoxy, the paper becomes translucent and the wood grains shows through.
Brush on your second coat. Immediately, roll your graphic onto the board and use a stiff edge to carefully smooth it against the board. Brush more epoxy on top of the graphic.
Step 8: Peeling Graphic
Step 9: Cure Epoxy
Step 10: Trim Fiberglass
Step 11: Sand Edges
Step 12: Clean Out T-nuts
Step 13: Make and Install Foot Pads
Step 14: Ride
Throw caution to the wind and go crazy with huge jumps knowing your plywood ride will shoot you back upwind.
Laugh at people on the beach who spent $700 on their board and who feel compelled to tell you, "that won't work."