Step 1: Start Building the Skateboard
1. Place the first laminate on the foam mold.
2. Spread the skateboard glue on the first layer.
3. Place the second laminate on top of the first.
4. Spread the skateboard glue on the second layer.
5. Place the third laminate on top of the second.
6. Insert guide pin.
7. Slide the assembly into the netting.
8. Slide the assembly into the vacuum bag, seal the bag, and pump out all the air.
Step 2: Create Channel for Wires
1. After 24 hours remove the first three laminates from the vacuum bag.
2. Cut a channel/groove into the fourth laminate.
3. Add glue to the top of the first three laminate.
4. Place the fourth laminate on top of the assemble.
5. Place the assembly onto the foam mold, insert guide pin.
6. Place the entire assembly into the netting, then vacuum bag, and vacuum all the air out again.
Step 3: Add Wires and Complete Skateboard Assembly
1. After another 24 hours remove the assembly from the bag.
2. Tape/clamp the remaining three laminates together.
3. Drill holes in the last three laminates at the location of the LEDs and circuit board. Note: I used the TLAR (that looks about right) method for locating the holes.
4. Tape the wires into the groove.
5. Glue and add the last three laminates to the assembly, while pulling the wires through the holes that were drilled.
6. Slide into netting and vacuum bag for the last time.
Step 4: Build the Circuit
Edited: Here is the YouTube video:
Step 5: Build Housings
Step 6: Adding the Artwork
1. Cut the comic book pages into manageable sections.
2. Soak the sections in Polycrilic.
3. Apply to the board using a flexible plastic spreader.
4. Wait two hours then apply the Ink Jet Stickers. Stickers are sealed with Acrlyic sealer before Poly is added.
5. Apply coat of Polycrilic.
6. Wait two hours then sand the Poly with 220 grit sand paper.
7. Repeat steps 5 and 6 until you can no longer feel the edges of the paper. Note: In several places I sanded through the Poly and damaged the comics/art, this "accident" added character to the board and if I did it again I would not avoid sanding through.
8. Once the edges could no longer be felt, I switched to 320 grit sand paper, then added two more layers of Poly.
9. A wet layer of Poly was added to the top of the board, Tread Tex was sprinkled onto the board using a salt shaker.
10. Two more layers of Poly were added to the top of the Tread Tex.
11. The entire board was sprayed with a clear gloss Acrylic sealer.
This entire process took almost two weeks.
Step 7: Make LED Assemblies
1. Insert eight white LEDs into one strip, attach using 5 minute epoxy.
2. Solder all anodes together.
3. Repeat steps one and two with the red LEDs.
Step 8: Putting It All Together
1. Solder the LEDs to the wires that are sticking out of the housings. Make a note of what color wires goes to what LED.
2. Attach the wires to the circuit board.
3. Install batteries and test the circuit before gluing anything permanent.
4. Glue the LED assemblies to the housings.
5. Glue the battery boxes to the skateboard.
6. Drill holes for the switches and install the switches.
7. Create a barrier between the circuit board and batteries.
8. Mix and pour the potting epoxy.
9. Drill the holes for the trucks.
10. Install the trucks and wheels.
11. Ride and enjoy.
Edited: here is the YouTube video:
Attached is a short video of Josh (the 13 year old) riding the board in the dark. The video was hard to shoot in the dark with the bright LEDs, but Josh claims they make it much easier to ride at night.