Readers will know that I was intent on shaping a surfboard out of pink foam insulation. I went to Home Depot, and bought 2″ and 1″ pieces. Once home, I mixed up a batch of epoxy and sandwiched it between the two pieces of foam; placing the thinner sheet on top. To guarantee good adhesion I moved the top sheet back and forth a few times. Then I busted out my old encyclopedia collection; I placed a few books under the nose and the rest on top. This step is critical as it sets the main rocker for the whole board! I let it dry overnight and removed the books in the morning. As expected, the rough rocker and shape stayed!
Now, at this point I could have added a stringer, but to be honest, I was still unsure of how to do it. So instead, I just went at that block of foam like a pit bull on a piece of meat! I got the rough dimensions from a buddy of mine that has a similar fish and I watched a half dozen Youtube videos on shaping. My pucker was so tight on the first pass I barley took off any material. It took a bunch of light passes with the planner to really get a good feel for it but once you figure it out, it makes more sense and is way easier than it looks. Side bar tip: Foam dust is wicked itchy and it dries out your hands like crazy! A vacuum system on your planer would be a worth while investment…if not buy a Tyvek suit for a couple bucks and wear some goggles and a respirator!
I found that the planer is a great for getting your rough shape but the real magic tool to dial in the body is a Sureform. Know it, love it, live it….there is a slight learning curve with these as well so do a couple test passes on some scrap first. A horizontal pattern tends to work best for me but everyone’s opinion differs.
For me, finding symmetry was the toughest part. With this project I had no stringer which meant no centerline!!! I shaped most of it off of feel and sight although snapping a chalk line from the tip of the nose to the center of the V in my swallow tail helped temporarily. After another visit to Home Depot, I started my sanding process by using a 60 grit drywall sanding screen attached to a long wood block. A few passes with this and your excitement really starts to grow! The foam takes on a super smooth and soft feel and I can remember saying to myself… “it’s really starting to look like a board!”. I worked my way all the way up to 220 grit getting the deck and hull as smooth as a baby’s ass! The rails can be touchy, just go slow and use a screen by itself.
Finally, I was done. The shape was perfect and it really looked like a surfboard!!! However, when I went to pick it up I was blown away how much flex there was…there was too much, it felt weak and I thought it was going to snap! This was due to the lack of a stringer so I had to think on the fly….Back to Home Depot!
Click on the link for Part 3 of the Home Depot Surfboard Shaping Odyssey
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looks good..
DUDE, that thing is sick! I’m going to Home Depot!!!!