I have wanted to make a longboard deck for some time, however I was having trouble finding cheap veneers. I started thinking about using popsicle sticks to construct my own veneers instead. Popsicle sticks are made from baltic birch, which is used to make wooden aircraft so I thought It might work for a longboard as well. Here's what I did.

Step 1: Shaping the template

I figured out the shape I wanted and scaled it so i could use 5 sheets of 8 1/2 x 11" paper as a template. I just taped the sheets together cut it out and stood beside it to make sure it felt right.
<p>wow that must be so strong even though thay are lolly pop sticks</p>
Okay.. So I know alot of people just use regular sheets of Baltic both and the bend the wood I a pres and glue em together.. Well would it work to make say 2-3 sheets of these flat veneers and then glue em together normally ? Like due 2layers for each&quot;veneer&quot;. One with the grain and one against? If that would work it would be easier to sculpt out then boiling the sticks.. But would it break easier? Idk.. Please get back to me!!! <br>
<p>did you ever end up doing this? how well did it work? i was thinking the same thing.. thanks in advance for any input</p>
Sorry, I don't understand what you are asking.
Sorry I'm on iPad and autocorrect gets me sometimes.. I mean could you make flat sheets of Popsicle stick &quot;veneers&quot; and the glue those together in a mold? And for the veneers do one layer horizontal and one layer vertical... If that's more clear please respond.. I want to make flat to skip the whole bending the Popsicle step.. Thanks in advanced..
You could try it, make a few small veneers and test it.
Okay thanks sounds good.. I might just try it!
<p>Love this build - YOU ARE THE MAN!! - so many great aspects too this.</p><p>I'm quite heavy so could add layers to allow for this.</p><p>Extra materials could be added between layers for say more or less rigidity.</p><p>The turning should be great due to the natural flexibility ( in the vid ) and it looks like pumping is nice too.</p><p>Damage to the top or bottom could be easily fixed, plus any breaks should not spread like grain might.</p><p>Really liked the vacuum idea too.</p><p>Really great job.</p>
Where did you get the thin air press?
<p>cool stuff!</p>
Sorry this is late, but wouldn't it have been faster to make plies out of the Popsicle sticks, and then to press the design?
<p>Well, now I just have to wait till summer comes so I could collect all the popsicle sticks! :D Great job and briliant idea! :)</p>
Start a company.<br>
looks... good
i would do that but I already made my board just need to put every thing to it
Do you have to use a vacuum bag? or can you use just pressure?
You need a 2 part mold if you don't want to use the vacuum bag. The bags are available at most dollar stores.
could it be possible to make a regular plywood core and then simply put a layer of popsicle sticks on the bottom? i like the look of the popsicle sticks, i just dont have that kind of patience :P
hey just wonderin how do you like the sabre trucks btw?
I really like them. They are super stable and have a real feeling of control!
Absoulutely fantastic!
Would it be possible to do this in a herringbone pattern?
A herringbone pattern would look great on the outside layers! It would be considerably more work, but most likely worth the effort.
How many and what size were your foam core sheets
I bought 3 sheets 24&quot; x 36&quot; 1/4&quot; sheets, however I only used 2 of them.
About how much did it cost you to make this? I have a friend who would probably try to make one but is alas a poor college student.
The cost to make the board was around $40 not including skateboard trucks, wheels, bearings, and hardware.
you could put a layer of fibre glass on to add a bit more strength and stiffness but also give a bit more spring.<br>
I make custom longboards, and this project seams very out of the box. For at least I wouldve just gone and bought some sheets of BB ply but the bottom design was tight with the popsicles. it was almost like hard wood floor. Ill be making an instructable on how to press with sheets of baltic birch. Very nice. Itll be interesting to see how your board does over time.
So after the first layer was done did you peel it off the vinyl or did you leave the vinyl on the finished product?
The vinyl was only adhered to the foam core mold. The vinyl is glossy and keeps the glue from sticking to the mold so that the first layer (bottom) can be easily removed from the mold.
So later you replaced that with the wax paper, which then brings to question...how weel did the wax paper work?
The wax paper was only used to separate the layers from one another during the glueing of the layers, it was later peeled of and sanded away before the final glue up.
you rock! thisdeck is absolutely incredible. when i saw the title that it was made form popsicle sticks i thought it was either a joke or it sucked. boy was i wrong! i may try it if i come across a lot of time but you have pure talent man. it looks great.
That thing has a gnarly big tail. Was it worth all the work? How durable is it?
Totally worth the work! It seems to be holding together quite well!
Looks awesome! <br><br>Could you please provide more info on the flex of the board? Could you also state the thickness of the board after completion?<br>
The board is 1cm thick. I weigh 190lbs and it supports me with some flex. If you want a stiffer popsicle stick longboard do seven layers instead of five. A seven layer board would be around 1.4 cm thick.
i really am looking forward to doing this project! however i don't know skate stuff very well, can you tell me exactly what hardware you got for this?<br>
190 mm Sabre trucks and OJ 60 mm &quot;Hot Juice&quot; wheels. Minilogo bearings and Shorty's 1&quot; bolts.
thanks, I'm really excited to try this, I've wanted a longboard for a while now!
WOW great job!
Do you get wheel bite at all?
Nope, no wheel bite.
I'm a little confused- it seems you didn't use a core. In the first post I heard you call the popsicle sticks a veneer, but overall I never saw any talk about what sort of core material you had in the board. Since you also mention &quot;make it 7 layers not 5 for a trick board,&quot; I'm thinking that you made the *whole thing* out of popsicle sticks. That's tremendous. But...Why? I feel like there has to be some cheap strong material you could throw in the middle to give it a little more strength.<br><br>Sweet instructable, though
It is completely popsicle sticks. The more layers the more rigid the deck will become. Instead of buying veneer sheets I decided to make my own. It definitely is possible to use something else as a core material but I wanted to use popsicle sticks exclusively.
I see. I was confused because veneer is, as far as I'm aware, something usually layered on top of a core material (for instance, the cheap veneer on top of the super cheap core of my desk). But I guess vaneer sheets must just be the terminology in making these layered decks. Thanks for the reply &amp; clarification!
A veneer is simply just a thin layer of material (usually wood) that is either glued onto another (cheaper) material specifically for the look of the veneer or multiple layers are glued together to form a plywood. It doesn't actually have to be on top of something else to be a veneer. If there's a core material involved, it's usually to cut down on costs but occasionally is used for strengthening the end product.

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Bio: I'm a video editor by trade but enjoy making all kinds of things to entertain myself and others.
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