loading
Learn to shape a surfboard from the famous Johhny "V" Voxlund in Haiku Maui.

Other episodes of this project:
Build A Surfboard Episode 2: Sanding and
Episode 3: Laminating and Vacuum Bagging

Johnny starts with a urethane foam "blank" he gets at a local supplier "Fiberglass Hawaii".
The blank is made by "US Blanks". He asked for the 9'5" blank with the maximum "rocker".
Rocker is the curve of the bottom that makes a board look like a banana from the side.

The workbench or "rack" supporting the board in this photo is padded with carpet scraps. It allows him to support the board on its edge or flat like a table while shaping. The fluorescent sidelights lining the room at elbow height let him see the smallest irregularity or bump on the board's bottom.

Johnny shaped surfboards and windsurfing boards fulltime for many years and has worked as "shadow shaper" for other famous shapers. Now he only makes a few boards a year. He charges a couple of thousand dollars for a board. He specializes in high end custom boards for discerning amateur surfers. He says "people pretty often think they're bad surfers. Usually it's the board that's bad. There's been a revolution in board design in the past few years."

Words music and photos by Star & Tim.

Step 1: Blanks

A "blank" is a block of foam shaped like a surfboard. Usually a blank contains one or more "stringers" which are lengthwise strips of wood that give the middle of the board extra strength.

Here's Fiberglass Hawaii's stock of blanks at their store in Kahului Maui.
These are mostly made by "US Blanks", which is a new company.
Until a few years ago a company "Clark Foam" made 90% of the blanks in the world. They molded a huge variety of blanks so you could order one very close to any shape you wanted. The molds are made of two large pieces of concrete with a hollow cavity between. Two-part urethane is mixed and poured into the mold which is clamped shut. The urethane expands and puts huge pressure on the mold. The amount of urethane put into the mold determines the density of the blank. The concrete mold prevents it from expanding too much and being soft. After the blank is taken out of the mold, it's sawed down the middle and a thin wooden "stringer" is glued in place.

In 2005 "Grubby" Clark, the founder of Clark Foam unexpectedly closed his business and smashed his hundreds of molds with an earth-moving machine. That caused a shortage of blanks in the industry. Many shapers couldn't make boards. Some shapers started experimenting with styrofoam and natural materials for their surfboards. Several new urethane blank manufacturers have started up, but it's still not possible to get the range of blanks Clark used to carry.

Johnny now has to order a much larger blank and cut off a lot more foam than he used to.
Many shapers use computer-controlled milling machines to make their boards. They don't care how thick the blank is to start out. A rectangular block would be fine for them.
OMG I LOVE THIS!!! I don't get to surf too often but I'm going to try to do it more. Ever since i went surfing in Hawaii a few weeks ago and came back to the Coast I haven't stopped thinking about surfing. It makes me feel so happy and free :D
thank you! I like this news, I also have information to share, here is my message.we sale 60%-80% discount <br><a href=" http://www.mbts.es/">mbt</a> <br><a href="http://www.ugg-boot.nl/">ugg boots</a> <br><a href="http://www.ugg-boot.nl/">cheap uggs</a> or <br><a href="http://www.ugg-boot.nl/">uggs</a> or <br><a href="http://www.ugg-boot.nl/">ugg</a> or <br><a href="http://www.fr-tiffany.com/">tiffany</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie</a> <br><a href="http://www.monclerjeans.com/">moncler</a> or <br><a href="http://www.aboutcl.com/">christian louboutin</a> or <br><a href="http://www.aboutcl.com/">cheap christian louboutin</a> <br><a href="http://www.aboutcl.com/">christian louboutin shoes</a> or <br><a href="http://www.airmaxtop.com/">air max shoes</a> or <br><a href="http://www.airmaxtop.com/">cheap air max shoes</a> or <br><a href="http://www.airmaxtop.com/">nike air max</a> or <br><a href="http://www.airmaxtop.com/nike-air-max-90-c-47.html">air max 90</a> or <br><a href="http://www.airmaxtop.com/nike-air-max-90-c-47.html">nike air max 90</a> or <br><a href="http://www.oppell.com/">air max</a> or <br><a href="http://www.oppell.com/">air jordan</a> or <br><a href="http://www.oppell.com/">air max shoes</a> or <br><a href="http://www.oppell.com/">air jordan shoes</a> or <br><a href="http://www.oppell.com/">nike air max</a> or <br><a href="http://www.oppell.com/">cheap air max</a> or <br><a href="http://www.oppell.com/">cheap air jordan</a> or <br><a href="http://www.us-linksoflondon.com/">links of london</a> or <br><a href="http://www.uggmanor.com/">UGGアグ</a> or <br><a href="http://www.uggmanor.com/">UGG</a> or <br><a href="http://www.mbtshop.jp/">mbt</a> or <br><a href="http://www.mbtfan.com/">mbt</a> or <br><a href="http://www.mbtcute.com/">mbt</a> or <br><a href="http://www.cheapestmbt.com/">mbt</a> or <br><a href="http://www.mbthere.com/">mbt</a> or <br><a href="http://www.us-linksoflondon.com/">links of londons</a> or <br><a href="http://www.us-linksoflondon.com/">cheap links of london</a> or <br><a href="http://www.us-linksoflondon.com/">Links of London Jewelery</a> or <br><a href="http://www.us-linksoflondon.com/">Links of London Jewellery</a> or <br><a href="http://www.fr-tiffany.com/">tiffany &amp; co</a> or <br><a href="http://www.fr-tiffany.com/">tiffany Jewelry</a> or <br><a href="http://www.fr-tiffany.com/">cheap tiffany Jewelry</a> or <br><a href="http://www.fr-tiffany.com/">tiffany Jewellery</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie fitch</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie &amp; fitch</a> or <br><a href="http://www.abercrombiefitchcloth.com/">cheap Abercrombie</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie fitch clothing</a> <br><a href="http://www.monclerjeans.com/moncler-pants.html">Moncler Pants</a> <br><a href="http://www.monclerjeans.com/moncler-pants.html">Moncler Pant</a> <br><a href="http://www.monclerjeans.com/moncler-scarf-caps.html">moncler scarf caps</a> <br><a href="http://www.monclerjeans.com/moncler-scarf-caps.html">moncler scarf</a> <br><a href="http://www.monclerjeans.com/moncler-scarf-caps.html">moncler caps</a> <br><a href="http://www.monclerjeans.com/moncler-bags.html">moncler bags</a> <br><a href="http://www.monclerjeans.com/moncler-bags.html">moncler handbags</a> <br><a href="http://www.monclerjeans.com/moncler-bags.html">moncler bag</a> <br><a href="http://www.monclerjeans.com/moncler-boots.html">Moncler boots</a> <br><a href="http://www.monclerjeans.com/moncler-boots.html">Moncler boot</a> <br><a href="http://www.monclerjeans.com/moncler-slippers.html">moncler slippers</a> <br><a href="http://www.monclerjeans.com/moncler-slippers.html">moncler slipper</a> shoes、clothing、Jewellery、bag、Watchs。
thank you! I like this news, I also have information to share, here is my message.we sale 60%-80% discount <br><a href=" http://www.mbts.es/">mbt</a> <br><a href="http://www.ugg-boot.nl/">ugg boots</a> <br><a href="http://www.ugg-boot.nl/">cheap uggs</a> <br><a href="http://www.ugg-boot.nl/">uggs</a> <br><a href="http://www.ugg-boot.nl/">ugg</a> <br><a href="http://www.fr-tiffany.com/">tiffany</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie</a> <br><a href="http://www.monclerjeans.com/">moncler</a> or <br><a href="http://www.aboutcl.com/">christian louboutin</a> or <br><a href="http://www.aboutcl.com/">cheap christian louboutin</a> <br><a href="http://www.aboutcl.com/">christian louboutin shoes</a> or <br><a href="http://www.airmaxtop.com/">air max shoes</a> or <br><a href="http://www.airmaxtop.com/">cheap air max shoes</a> or <br><a href="http://www.airmaxtop.com/">nike air max</a> or <br><a href="http://www.airmaxtop.com/nike-air-max-90-c-47.html">air max 90</a> or <br><a href="http://www.airmaxtop.com/nike-air-max-90-c-47.html">nike air max 90</a> or <br><a href="http://www.oppell.com/">air max</a> or <a href="http://www.oppell.com/">air jordan</a> or <br><a href="http://www.oppell.com/">air max shoes</a> or <br><a href="http://www.oppell.com/">air jordan shoes</a> or <br><a href="http://www.oppell.com/">nike air max</a> or <br><a href="http://www.oppell.com/">cheap air max</a> or <br><a href="http://www.oppell.com/">cheap air jordan</a> or <br><a href="http://www.us-linksoflondon.com/">links of london</a> or <br><a href="http://www.uggmanor.com/">UGGアグ</a> or <br><a href="http://www.uggmanor.com/">UGG</a> or <br><a href="http://www.mbtshop.jp/">mbt</a> or <br><a href="http://www.mbtfan.com/">mbt</a> or <br><a href="http://www.mbtcute.com/">mbt</a> or <br><a href="http://www.cheapestmbt.com/">mbt</a> or <br><a href="http://www.mbthere.com/">mbt</a> or <br><a href="http://www.us-linksoflondon.com/">links of londons</a> or <br><a href="http://www.us-linksoflondon.com/">cheap links of london</a> or <br><a href="http://www.us-linksoflondon.com/">Links of London Jewelery</a> or <br><a href="http://www.us-linksoflondon.com/">Links of London Jewellery</a> or <br><a href="http://www.fr-tiffany.com/">tiffany &amp; co</a> or <br><a href="http://www.fr-tiffany.com/">tiffany Jewelry</a> or <br><a href="http://www.fr-tiffany.com/">cheap tiffany Jewelry</a> or <br><a href="http://www.fr-tiffany.com/">tiffany Jewellery</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie fitch</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie &amp; fitch</a> or <br><a href="http://www.abercrombiefitchcloth.com/">cheap Abercrombie</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie fitch clothing</a> <br><a href="http://www.monclerjeans.com/">cheap moncler</a> <br><a href="http://www.monclerjeans.com/">moncler clothing</a> <br><a href="http://www.monclerjeans.com/">cheap moncler clothes</a> <br><a href="http://www.monclerjeans.com/">cheap moncler clothing</a> <br><a href="http://www.monclerjeans.com/moncler-jackets-kid.html">Moncler Jackets Kid</a> <br><a href="http://www.monclerjeans.com/moncler-jackets-kid.html">Moncler Jackets kids</a> <br><a href="http://www.monclerjeans.com/moncler-jackets-kid.html">Moncler Kid</a> <br><a href="http://www.monclerjeans.com/moncler-jackets-kid.html">Moncler Kids</a> shoes、clothing、Jewellery、bag、Watchs。
thank you! I like this news, I also have information to share, here is my message.we sale 60%-80% discount <br><a href=" http://www.mbts.es/">mbt</a> <br><a href="http://www.ugg-boot.nl/">ugg boots</a> <br><a href="http://www.ugg-boot.nl/">cheap uggs</a> or <br><a href="http://www.ugg-boot.nl/">uggs</a> or <br><a href="http://www.ugg-boot.nl/">ugg</a> or <br><a href="http://www.fr-tiffany.com/">tiffany</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie</a> <br><a href="http://www.monclerjeans.com/">moncler</a> or <br><a href="http://www.aboutcl.com/">christian louboutin</a> or <br><a href="http://www.aboutcl.com/">cheap christian louboutin</a> <br><a href="http://www.aboutcl.com/">christian louboutin shoes</a> or <br><a href="http://www.airmaxtop.com/">air max shoes</a> or <br><a href="http://www.airmaxtop.com/">cheap air max shoes</a> or <br><a href="http://www.airmaxtop.com/">nike air max</a> or <br><a href="http://www.airmaxtop.com/nike-air-max-90-c-47.html">air max 90</a> or <br><a href="http://www.airmaxtop.com/nike-air-max-90-c-47.html">nike air max 90</a> or <br><a href="http://www.oppell.com/">air max</a> or <br><a href="http://www.oppell.com/">air jordan</a> or <br><a href="http://www.oppell.com/">air max shoes</a> or <br><a href="http://www.oppell.com/">air jordan shoes</a> or <br><a href="http://www.oppell.com/">nike air max</a> or <br><a href="http://www.oppell.com/">cheap air max</a> or <br><a href="http://www.oppell.com/">cheap air jordan</a> or <br><a href="http://www.us-linksoflondon.com/">links of london</a> or <br><a href="http://www.uggmanor.com/">UGGアグ</a> or <br><a href="http://www.uggmanor.com/">UGG</a> or <br><a href="http://www.mbtshop.jp/">mbt</a> or <br><a href="http://www.mbtfan.com/">mbt</a> or <br><a href="http://www.mbtcute.com/">mbt</a> or <br><a href="http://www.cheapestmbt.com/">mbt</a> or <br><a href="http://www.mbthere.com/">mbt</a> or <br><a href="http://www.us-linksoflondon.com/">links of londons</a> or <br><a href="http://www.us-linksoflondon.com/">cheap links of london</a> or <br><a href="http://www.us-linksoflondon.com/">Links of London Jewelery</a> or <br><a href="http://www.us-linksoflondon.com/">Links of London Jewellery</a> or <br><a href="http://www.fr-tiffany.com/">tiffany &amp; co</a> or <br><a href="http://www.fr-tiffany.com/">tiffany Jewelry</a> or <br><a href="http://www.fr-tiffany.com/">cheap tiffany Jewelry</a> or <br><a href="http://www.fr-tiffany.com/">tiffany Jewellery</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie fitch</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie &amp; fitch</a> or <br><a href="http://www.abercrombiefitchcloth.com/">cheap Abercrombie</a> or <br><a href="http://www.abercrombiefitchcloth.com/">Abercrombie fitch clothing</a> <br><a href="http://www.monclerjeans.com/moncler-pants.html">Moncler Pants</a> <br><a href="http://www.monclerjeans.com/moncler-pants.html">Moncler Pant</a> <br><a href="http://www.monclerjeans.com/moncler-scarf-caps.html">moncler scarf caps</a> <br><a href="http://www.monclerjeans.com/moncler-scarf-caps.html">moncler scarf</a> <br><a href="http://www.monclerjeans.com/moncler-scarf-caps.html">moncler caps</a> <br><a href="http://www.monclerjeans.com/moncler-bags.html">moncler bags</a> <br><a href="http://www.monclerjeans.com/moncler-bags.html">moncler handbags</a> <br><a href="http://www.monclerjeans.com/moncler-bags.html">moncler bag</a> <br><a href="http://www.monclerjeans.com/moncler-boots.html">Moncler boots</a> <br><a href="http://www.monclerjeans.com/moncler-boots.html">Moncler boot</a> <br><a href="http://www.monclerjeans.com/moncler-slippers.html">moncler slippers</a> <br><a href="http://www.monclerjeans.com/moncler-slippers.html">moncler slipper</a> shoes、clothing、Jewellery、bag、Watchs。
Thanks for the awesome surfboard guide. Shapers rock!<br> <br> <a href="http://surfboardsale.com.au">The Great Australian Surfboard Sale</a>
Examine the soles of your shoes. Note where <a href="http://www.cheap-uggs-boots.com/ugg-mini/" rel="nofollow"><strong>UGG Mini</strong></a> wear has occurred. Most people seem to be amazed that their shoes wear at the rear outer corner. Most <a href="http://www.cheap-uggs-boots.com/ugg-mini/" rel="nofollow"><strong>UGG Mini boots</strong></a> rearfoot strikers will wear at this part of the shoe. The reason for this, which someday, somewhere a funded study will prove, is that for most heel strikers it is the point <a href="http://www.cheap-uggs-boots.com/ugg-mini/" rel="nofollow"><strong>Mini ugg boots</strong></a> of first contact of the shoe with the ground. Most people walk and run with their feet slightly rotated from center. Runners, however, also have what is called a narrow base <a href="http://www.cheap-uggs-boots.com/ugg-mini/" rel="nofollow"><strong>Mini uggs</strong></a> of gait. A narrow base of gait means that the feet contact close to the midline of your body. This creates additional varus (tilting in) of the limb. This results, for the rearfoot striker, in the first point hitting the ground being the outer corner of your shoe. Forefoot wear <a href="http://www.cheap-uggs-boots.com/ugg-mini/" rel="nofollow"><strong>ugg 5854</strong></a> may point to an individual who is a sprinter, runs fast, contacts the ground with the forefoot first or all of the above. Uneven forefoot wear may show where one metatarsal is plantarflexed relative to the others or where one metatarsal may be longer than the others. In the presence of significant forefoot wear, you are at risk of stress fractures.
where can you get blanks at?
Freakin' Awesome 'ible. Thanks!
That is excellent, and I love the workshop, it's just awesome!
Excellent job, thanks!<br/><br/>The rise, dominance and self-imposed fall of &quot;Grubby&quot; Clark is fascinating. Here's a <a rel="nofollow" href="http://www.getoutdoors.com/goblog/index.php?/archives/203-Endless-Summer-On-Hold-Surfboard-Makers-Shooting-Blanks.html">copy of his 'I'm-quiting-the-biz' fax</a> and a link with <a rel="nofollow" href="http://www.surfline.com/surfnews/article.cfm?id=1624">many opinions about the man and his motives...</a><br/>
Sweet! I get told I should make surf boards... I can't wait for the rest of the series! :D
I can't wait for the next steps. This is really neat. :D
Wow! Now if only i lived near some water...

About This Instructable

46,095 views

160 favorites

License:

Bio: Tim Anderson is the author of the "Heirloom Technology" column in Make Magazine. He is co-founder of www.zcorp.com, manufacturers of "3D Printer" output ... More »
More by TimAnderson: 磨刀的技巧 Tricks zum Messerschärfen ナイフの研ぎ方のこつ
Add instructable to: