How to make a drop-down longboard using only simple woodworking tools?
The traditional technology of making a drop-down longboard requires a veneer pressing process. So it requires a special equipment. I offer to make a sectional longboard using flat plywood sheets with an optimized drop-down parts design. I described the principles in the following articles:
Forked drop-down longboard
Combined drop-down longboard
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Step 1: Gather Tools and Materials
To complete this project you will need the following materials and stock parts.
- 15mm (11 ply) Baltic birch plywood
- 12mm (9 ply) Baltic birch plywood
- Wood stain and varnish
- 180 mm (7") longboard trucks
- 65-70mm longboard wheels
- M5 (US #10-#12) bolts washers and nuts.
I recommend using the Caliber 184/50 or Slant 180/50 trucks for this design.
- Jigsaw with blades for plywood or laminate
- Electric drill with 5mm (US #12) bits
- Drill mount sanding disk or another sanding tool
- Sandpaper Scissors
- Glue stick
- Electric handheld router (optional).
Step 2: Download Project Files
Step 3: Cut Plywood Parts
Print part plans from the Forked_Drop-Down_Longboard.dxf file with the 1:1 scale. Glue them on the plywood sheets. Then cut the parts using jigsaw. Make the main platform of 15mm plywood and nose/tail parts of 12 mm plywood.
Step 4: Finish Plywood Parts
Remove paper plans from the plywood parts with a wet sponge and dry the parts. Refine part edges with sandpaper disk and electric router. Sand part surfaces with sandpaper.
Color parts with wood stain and then coat them with acrylic or yacht varnish.
Step 5: Assemble the Longboard
Mount trucks to the nose and tail parts. Attach these assemblies to the main platform. Don't forget to put washers under bolts and nuts. Optionally you can put washers between nose/tail parts and the main platform to adjust the platform drop level. Attach wheels.
All is done! The longboard is ready to ride.