So I am in the long portions of building a paddle board and had some scraps from it and wanted to match this to my board and instead of hoarding them away and loosing them I decided it would be a nice break and i could do a project that I could finish.
So here we go hope you enjoy
grinder with sanding head
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Step 1: Cut Strips of Scrap Wood
So this step you can make whatever width you want I didn't even measure but if I was to guess it would be around 3/8 inch just make sure you cut all the strips the same width also make sure the but joints are cut at 90. If you see from the picture I have some gaps in the wood this is because I did not follow my instructions and the wood did not join properly. no biggy we are using epoxy and it will fill the voids.
Step 2: Cut Pattern Out
I did a google search for printable paddle design and found this one it was smaller than i wanted so i just added 2 inches all the way around it and it looked correct to me so I went with it.
Step 3: Glue and Joint
so for me I decided to glue up small sections since my jointer can only handle 6 in pieces.
this is my proccess of gluing.
long strip on one side followed by little pieces then add a long piece on the other end this give the clamps 2 complete edege to clamp to and hold the small pieces tight and in place.
once the the glue has dried joint one 2 side so you have a flat surface to put against the table saw then cut just enough to make the edges flat
i did this step 5 times.
Step 4: Clap It Together
Using the template I arranged the pieces to match the template with room to cut off the excess.
Step 5: Trace Out the Design
I used a Sharpie so you could see it in the picture but a pencil would be just fine
Step 6: Cut Out the Paddle
its at this point i am starting to get excited about what i am making i can start to see a real life paddle!
Step 7: Shape the Paddle
Using an angle grinder I shaped the paddle leaving the center thicker than the side I dont know what I am doing but i just made it look the way i think it should.
after I got the general shape i used the orbital sander to clean up the grinder marks i used 60 all the way to 120
It could be a lie or my unwillingness to sand but I heard that the epoxy will bond better at 120. win win in my book
Step 8: Make the Handle
here I glue together strips to make the thickness 1 1/4 on all side I then ran it through the jointer on 2 side then to the table saw to sqaure it all up.
i then ran it thru the router table with the biggest round over bit i had then use the angle grinder to get a cirle shaft clean it up with palm sander.
when runing it through the router leave the top square to allow you yo glue the handle pieces to it.
Step 9: Cut 10 Degree Angle on the Miter Saw
This is an awkward cut to make so if you don't feel comfortable don't do it!! i then glued and clamp the paddle to the shaft using clamps to hold it tight.
Step 10: Sand It
Sanding is fun sanding is fun sanding is fun!! I hate Sanding
Step 11: Epoxy Time
this is one of the best parts of the job watching the color of the wood pop thru!!
I used 4 ounce fiberglass fabric with west system epoxy and its as clear as you can get it!!
Step 12: Sand It and Repeat on the Other Side
Step 13: Sand It and Then Add the Final Layer of Epoxy Down
Step 14: Test It
The paddleboard is still under construction so a pool float had to do! I added a photo of the board instructables coming soon