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.
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.)