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Picture of Popsicle Stick Longboard Deck
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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.

 
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Step 1: Shaping the template

Picture of Shaping the template
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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.

Step 2: Building the mold

I built a mold out of foam core or "Ready Board" which I bought at the dollar store. I cut out multiples with the curve I wanted with a scroll saw, these became the ribs of my mold. I scored the foam core with a razor blade so that the sheet could curve with the ribs. I marked out rib points with pencil and then I hot glued the ribs to the scored sheet.

To keep the popsicle sticks from sticking to the mold I covered the gluing surface with some glossy "marbled" vinyl I got at the dollar store.
I traced the template shape onto the vinyl and added a center line.

The curved tail section of the mold was built up of more pieces of foam core.

The illustraion shows a "cutaway" look of the mold. (Not the steps of construction.)

Step 3: Gluing the first layer

I purchased my glue and popsicle sticks. I used 2 bottles of Titebond III glue which I found at Lee Valley Tools. The popsicle sticks I purchased at the dollar store, they came in packages of 150 and were conveniently paper taped in stacks of 50. I figured I needed about 1500 sticks for the board but I had a lot of rejects.  I would say about a third of a package was unusable, either the sticks were warped or cracked.

I cut the round ends of the sticks off with a band saw.

I worked outward from the center of the mold gluing a row at a time. It was slow going, I figure I spent about 6-8 hours per layer.

Step 4: Steam bending for the tail 1

For the popsicle sticks to have a smooth curve into the tail of the longboard I needed to steam bend them.

For the first layer I left the tail until last. I dry fitted pieces and numbered them. I boiled water in a sauce pan and put a colander between the pan and it's lid, this would allow the steam to fill a chamber and transfer heat to the popsicle sticks so they could be bent.
They didn't need much time about 45 seconds to a minute in the steam was long enough to bend them. I had a few sticks break and had to replace them. After gluing the bent sticks in place I used a bag of sand on top of an extra piece of vinyl to help keep them in place while they dried.

For subsequent layers I would bend the tail pieces as I glued each individual line which worked much better.

Step 5: Steam bending for the second layer

For the second layer the popsicle sticks would be glued perpendicular to the first layer to add strength like plywood. This is called cross grain. Since the mold bends in that direction I needed to give the popsicle sticks for this layer a bend.

I built a jig that I could put a bunch of sticks into and steam at the same time. I placed the jig upside down above a large saucepan and covered some of the gaps with a rag. When steaming wood you want the steam to move around the wood. A steam chamber with a few holes in it is a good thing. The sticks only needed to be exposed to the steam for 45 seconds to a minute. Once they had cooled I popped them out and added another bunch.

I covered the first layer with wax paper so that the next layer wouldn't stick to it. I marked the center line with a push pin and started gluing my second layer.

Step 6: Steam bending for the tail 2

Picture of Steam bending for the tail 2
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For the next layer I glued as before except I did the tail pieces row by row. This worked much better, allowing me to work diagonally out from the tail pieces. I used a rasp to even out the ends of the popsicle sticks and some sand paper glued to a board to straighten the edges and to thin thicker sticks.

After each layer I sanded the high spots down and sawed of the excess at the tail.

Step 7: Gluing the layers and vacuum pressing

I made five layer total. Three lengthwise layers and two cross grain layers. I stacked them in an alternating pattern so that the bottom, middle, and top layers went lengthwise.

I used a palm sander to even out each layer. I peeled off the wax paper and sanded the undersides of each layer.

I reinforced the mold with some side pieces. Next was a dry fit, using a push pin as my center line I marked each layer with pencil so I knew where to place them when gluing and to see if they would fit in my vacuum bag.

I bought some vacuum bags meant for shrinking clothing for storage. Each package has small bags for shirts and large bags for dresses. The large bag was just too small for my mold so I had to cut off a 2 inch piece before I did the final glue up.

I applied a liberal amount of glue and used a brush to evenly smear the glue across the top of each layer top and also to the bottom of the next layer and stacked them in place on the mold.

I sealed the bag and vacuumed out the air you can see some extra glue seeping up through a crack in the top layer near the valve. Once again I used my trusty sand bag to apply extra pressure to the tail.

Step 8: Cutting out the shape

I left the mold in the the vacuum over night. After removing it from the vacuum I notice a couple of raised places which I would have to inject with glue after cutting the board out and sanding.

I used a jig saw to cut out the shape and used a belt sander to smooth the edges. Next was the palm sander to smooth and remove extra glue from the top and bottom. I used a damp cloth to clean off any fine saw dust that was left on the board.

Step 9: Preparing for hardware

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I added holes for the skateboard trucks with a drill press.

I bought trucks, wheels, bearings, grip tape, nuts, and bolts at a local skate shop. I decided a cool blue which reminded me of popsicles was a good colour choice for the wheels.

Step 10: Finishing

There was some more sanding needed on some spots on the top which were raised and needed to be injected with extra glue.  After that I sealed the board with a few coats of shellac and applied some surf inspired grip tape lines.  The grip tape is self adhesive and can be purchased at almost any skateboarding shop. 

Overall there are much easier and faster ways to build a longboard deck, but I wanted to try using popsicle sticks just to see if it was possible.

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MackeFeet3 years ago
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"veneer". 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!!!
iamfexd MackeFeet3 months ago

did you ever end up doing this? how well did it work? i was thinking the same thing.. thanks in advance for any input

nsnip (author)  MackeFeet3 years ago
Sorry, I don't understand what you are asking.
MackeFeet nsnip3 years ago
Sorry I'm on iPad and autocorrect gets me sometimes.. I mean could you make flat sheets of Popsicle stick "veneers" 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..
nsnip (author)  MackeFeet3 years ago
You could try it, make a few small veneers and test it.
MackeFeet nsnip3 years ago
Okay thanks sounds good.. I might just try it!
darrenhall6 months ago

Love this build - YOU ARE THE MAN!! - so many great aspects too this.

I'm quite heavy so could add layers to allow for this.

Extra materials could be added between layers for say more or less rigidity.

The turning should be great due to the natural flexibility ( in the vid ) and it looks like pumping is nice too.

Damage to the top or bottom could be easily fixed, plus any breaks should not spread like grain might.

Really liked the vacuum idea too.

Really great job.

Flash6710 months ago
Where did you get the thin air press?
Flash6711 months ago
Cool.
StasinG11 months ago

cool stuff!

jay z11 months ago
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?
Eldalote1 year ago

Well, now I just have to wait till summer comes so I could collect all the popsicle sticks! :D Great job and briliant idea! :)

dschiley1 year ago
Start a company.
Benjaay9991 year ago
looks... good
otmpp1 year ago
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?
nsnip (author)  yoyomasterjr2 years ago
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?
nsnip (author)  predatory meatball2 years ago
I really like them. They are super stable and have a real feeling of control!
Absoulutely fantastic!
cryophile3 years ago
Would it be possible to do this in a herringbone pattern?
nsnip (author)  cryophile3 years ago
A herringbone pattern would look great on the outside layers! It would be considerably more work, but most likely worth the effort.
jcrameri3 years ago
How many and what size were your foam core sheets
nsnip (author)  jcrameri3 years ago
I bought 3 sheets 24" x 36" 1/4" 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.
nsnip (author)  LadyKatianaTheBrave3 years ago
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.
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?
nsnip (author)  happyhour88913 years ago
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?
nsnip (author)  happyhour88913 years ago
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.
zomfibame3 years ago
cool!
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.
mrsalty1293 years ago
That thing has a gnarly big tail. Was it worth all the work? How durable is it?
nsnip (author)  mrsalty1293 years ago
Totally worth the work! It seems to be holding together quite well!
Looks awesome!

Could you please provide more info on the flex of the board? Could you also state the thickness of the board after completion?
nsnip (author)  AwesomeRhino3 years ago
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.
crazy4u2003 years ago
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?
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