Step 1: Materials and Tools Needed.
2 lengths of 25mm diameter steel tube
4 x star nuts to fit diameter of steel tube (see image)
4 x 35mm bolts to fit the star nuts
2 lengths of 35mm diameter PVC tube - this tube needs to have an internal diameter of a size sufficient for the steel tube to fit easily inside.
Kflex pipe insulation, or similar, to fit over the 35mm PVC pipe
self drilling wood screws of at least 40mm length
hacksaw with metal cutting blade or angle grinder
metal file - fine
various steel drill bits
cordless screw driver
Step 2: Measuring
If you normally store it in a cover, leave the cover on.
Measure the widest point of the board's (and cover's) width.
Add an additional 50 mm ( 2 inches) to this measurement and record.
Step 3: Cutting
Using an angle grinder or hacksaw, cut both steel tubes to length.
Clamp the PVC tubing and mark to a length 10mm or 1/2 inch shorter than the steel tube.
Cut to length.
Use a file to de-burr both the steel tube and the PVC tubing.
Step 4: Drilling
1. Clamp one bracket and enlarge the hole closest to one end, using a drill and drill bits.
2. Continue drilling with increasing drill sizes until the bolt fits into the hole easily.
3. Repeat for each bracket.
Step 5: Pre-assembly
2. Use the hammer to tap the end of the bolt to force the star nut inside the end of the steel tube.
3. Use the shifting spanner on the bolt head whilst holding the tube firmly. Continue to tighten until the steel tube pulls up firmly to the bracket.
4. Repeat for each bracket.
5. Dissemble to remove all bolts and brackets. If this step has been completed correctly, you will have bedded the star nuts in each end of both tubes.
6. Cut the pipe insulation to the same length as the PVC tubing using the utility knife.
7. Fit the pipe insulation over the PVC tubing. To make this easier, a few drops of dish washing detergent applied to the PVC tube will help.
Step 6: Selecting Your Mounting Position.
You will need to ensure the rack is not too close to a wall or you will not have sufficient room to manoeuvre the surfboard onto the rack.
1. Use a stud finder to locate the ceiling studs.
2. Mark the centre of the stud's width with a pencil.
3. Move along the stud a distance equal to the length of the steel tube. Again, locate the centre of the stud's width. These marks represent the outside edge of the brackets' placement.
4. Locate another stud approximately 1200mm (4 feet) to 1500mm (5 feet) from the stud already marked.
5. Repeat steps 2 and 3.
6. Take measurements from adjacent walls to ensure the brackets are positioned parallel to each other.
Step 7: Final Assembly.
2. Repeat for all brackets.
3. Slide the PVC tube over the steel tube.
4. Position the tubes, between the brackets, in line with the enlarged hole and use the bolts to attach. Tighten.
5. Repeat with the second tube and second set of brackets.
6. The PVC tubes should be able to roll freely on the steel tubes.
If you have surplus pipe insulation, pieces may be put over the arms of the shelf brackets pointing towards the floor before installing the roller bars. This will increase the protection offered to your surfboard. (This can be see in the photo in the final step on the double surfboard rack.)
Step 8: Use
Walk it onto the racks while elevating the tail.
Finally, grasp the fin to guide fully onto the rack.
To remove, reverse the above steps.
If you wish, these racks can be made to support two surfboards.
To do this, you need to begin with large shelf brackets.
Mount a second set of tubes half way between the end of the bracket and the ceiling. This works well with boards of differing lengths, with the longer board positioned on the top rollers.