Instructables
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 2: Building the mold

Picture of Building the mold
popsicle longboard mold making.jpg
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.)
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Flash6713 days ago
Where did you get the thin air press?
Flash6721 days ago
Cool.
StasinG24 days ago

cool stuff!

jay z26 days 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?
Eldalote4 months 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! :)

dschiley6 months ago
Start a company.
Benjaay9997 months 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)  yoyomasterjr1 year 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 meatball1 year ago
I really like them. They are super stable and have a real feeling of control!
MackeFeet2 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!!!
nsnip (author)  MackeFeet2 years ago
Sorry, I don't understand what you are asking.
MackeFeet nsnip2 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)  MackeFeet2 years ago
You could try it, make a few small veneers and test it.
MackeFeet nsnip2 years ago
Okay thanks sounds good.. I might just try it!
Absoulutely fantastic!
cryophile2 years ago
Would it be possible to do this in a herringbone pattern?
nsnip (author)  cryophile2 years ago
A herringbone pattern would look great on the outside layers! It would be considerably more work, but most likely worth the effort.
jcrameri2 years ago
How many and what size were your foam core sheets
nsnip (author)  jcrameri2 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)  LadyKatianaTheBrave2 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)  happyhour88912 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)  happyhour88912 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.
zomfibame2 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.
mrsalty1292 years ago
That thing has a gnarly big tail. Was it worth all the work? How durable is it?
nsnip (author)  mrsalty1292 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)  AwesomeRhino2 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.
crazy4u2002 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?
nsnip (author)  crazy4u2002 years ago
190 mm Sabre trucks and OJ 60 mm "Hot Juice" wheels. Minilogo bearings and Shorty's 1" bolts.
thanks, I'm really excited to try this, I've wanted a longboard for a while now!
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