I have always wondered how it would look and feel to ride a metal skateboard so recently I decided to build one. First off the reason I used aluminum is because of how heavy steel is, and also so it didn't rust because I think a large part of what makes this cool is the look. This board is extremely easy to build and all you really need is a sheet of aluminium metal and a few different tools!
.125 Thickness piece of Aluminium
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Step 1: Cutting the Board
So the first thing you are going to want to do is figure out you board size. I just measured out my actual board and cut it to that size. You should just simply cut a basic rectangle with the dimensions of the size of the board. Cutting the rectangle should be fairly easy, but make sure you are using a metal blade to cut it otherwise you will ruin the blade. For the aluminum piece thickness I would suggest going with .125 thickness.
Step 2: Cutting the Curves on the Board
This part is a little more tricky, but still not too hard and it doesn't need to be perfect. All that I did was kinda just drew out what I thought the curves on the sides of the board were and cut it out and it turned out great, simple as that.
Step 3: Grinding the Board to Perfection
This part is fairly straight forward and really only takes time. Grind all of the sides to make then slightly rounded to make sure the board's sides aren't razor sharp. Then grind the top and bottom to take away all the scratches on the board and to give it a cool metallic look. After this you are pretty much done.
Step 4: Bending the Board
Well honestly I tried to think of a better way to do it, but the best way is to literally wedge it between to things and just pull down as hard as you can. This surprisingly worked really well but its not the most elegant way of doing it.
Step 5: Lastly Add the Trucks
Well for this part just place the trucks where you want them and drill the holes then put them on pretty straight forward if you have ever put together a skateboard. Well that's it hope you enjoyed!