DIY Cruiser Board (no Power Tools Needed)

Hy guys. This is my first instructables. I am 16 and I am from Hungary.
This instructables is about building a cruiser board without any power tools. Keep in mind, that using power tools is less time consuming and the end result may turn out better, however it can be done with minimal equipment (this is also a challenge for me). I made a thick board, which is extra thick, but maybe I will use this board in the future to make an electric cruiser board. This project took me two and a half days to finish, but I am sure it can be done much faster!

Step 1: Tools and Materials

I used these tools, but -again- you can use power tools too.

Tools:

-Jigsaw

-Hand drill / screwdriver

-Knife

-Clamps (the more the better)

-Measuring tools

-Pencil and eraser

-Files

-Woodglue

-Varnish

-Spraypaint

-Superglue or any kind of strong all-purpose glue

Materilas:

-200mm / 600mm, 6mm thick plywood (3 pcs.)

-Sandpaper (instead of grip tape, but grip tape is much better)

-Wheels and Trucks

Step 2: Design and Cutout

There are many different sizes an shapes of board templates which you can use, but I decided to design my own board. It turned out to be 600mm in length and 180mm in width at the widest point.
The board narrows down to 150mm towards the tail.

Once you have your desired template, then apply it to the plywood.

NOTE: I didn’t glue the sheets together in the beginning, because I wanted to build in lights, but it didn’t work. Now the edge of the board isn’t looking so nice because of the excess glue, which dripped out at the sides.

Start by cutting out the rough shape with the jigsaw, which you can bring to shape later with the help of files. Be as precise as you can. It may take long, but take your time and don't work constantly, otherwise you will end up with big errors to correct. I took 5 min. breaks every time I felt tiredness.

Step 3: Shaping

As you can see my saw-work is terrible. I used a file with a rough and a fine side. Start with the rough one if you have big unevenness and use the fine side to finish it up. You can also round the edges of the board to make it look nicer. BE CAREFUL! Plywood can be chipped were easily. I didn’t pay enough attention to this fact and I have chipped it in many places.

Step 4: Gluing

Turning now to the gluing part, I recommend to use a very strong and watertight wood glue, however, if you keep your board away from water and moisture, then simple wood glue works just fine. To help the glue bind use as many clamps and weights as you can. I couldn’t find more clamps than 5 so later I had to put bricks on top of the deck. Leave it for 1 or 2 days to dry and wipe off any excess glue with a dank cloth in the beginning. After drying, check for any unglued parts and cracks and fill them in with the glue, to make sure it won’t separate by time.

Step 5: Drilling and Mounting

To drill the mounting holes I used the center line which I drew in the beginning and eyeballed their position. If you have a long ruler, then us it. You can use the base of your truck as a template. Mine turned out quite good and it ran fairly straight.
To drill the holes I used a ratchet screwdriver with a drilling mount and a 4mm bit. It wasn’t hard and I was done with the 8 holes in under 5 minutes.

At this point you should assemble the board and bring it on a test run. If it pulls to one of the sides, then try to reposition the mounting holes or extend them with a small file.

Step 6: Varnishing

If you want to use your board anytime and anywhere, it’s a good idea to coat the wood with one or two layers of varnish.

Step 7: Painting and Grip Tape

If you want to give your board a color it is good to be done now, before applying the grip tape. My color of choice is brown, but any other color works fine as well. If you can find a water resistant paint, then that is the best. Give your board a few coats and let it dry. Be sure to do this in a well-ventilated area and wear a mask if you can.

Apply the grip tape (or the sandpaper) and poke out the holes for the mounting screws. Use a sharp knife, razor blade or a box cutter to cut away any excess grip tape. Hold your blade in a slight angle to make it flush with the boards edge.