How to Shape a Surfboard

Shaping your board is not nearly as hard as you may think. You can shape your own surfboard just for fun, because it's cheaper, or if you want a specific shape.


  1. Image titled Shape a Surfboard Step 1
    Choose the shape for you board. The best way to simplify the decision is to ride as many different surfboards as possible. This is very important. One hour of surfing a different board is better than ten hours reading about design, or listening to opinions.
  2. Image titled Shape a Surfboard Step 2
    Be informed about surfboard design. The following things matter:
    • A relatively wide, thick, long, flat shape is generally better for small or slow waves
    • A relatively narrow, thin, short is generally better for fast, hollow, or large waves.
  3. Image titled Shape a Surfboard Step 3
    Decide on Styrofoam. Do you want to use Styrofoam? It has a density:40 to 60 kg/m3 Its advantages and drawbacks are:
    • Advantages : Hard, compatible with all resins, whiter than other Styrofoam; You can buy it pre-shaped.
    • Drawbacks: Heavier, expensive
    • Shapes only with a grater or a lathe.
  4. Image titled Shape a Surfboard Step 4
    Decide on using extruded polystyrene . It has a density:10 to 35 kg/m3
    • Advantages: cheaper, lighter, shape with a hot wire cutter
    • Drawback : beware you can not use resin for polyester, colour depends on supplier.
  5. Image titled Shape a Surfboard Step 5
    Find the foam. You can get the foam from a boat manufacturer.
  6. Image titled Shape a Surfboard Step 6
    Get the tools that you need :
    • grater
    • lathe
    • trestle
    • cutter
    • kitchen scales
    • scissors
    • pen
    • set? square
    • sandpaper
    • orbital sander
    • jigsaw
    • Hoover
    • goggles and gloves
  7. Image titled Shape a Surfboard Step 7
    Prepare the fibre glass. It has a base weight : 125 gr/m2 to 200 gr/m2
    • Pro surfer's boards have only one layer of 200gr fibre glass on the top and one layer of 125 gr fibre glass backside. But usually boars have two layer on the top (200 and 125) and two on the backside (200).
    • It depends on the solidity that you want. The best is to put 60% fibre and 40% resin but a beginner will put 50/50. It's will be a little bit heavier but it doesn't matter.
  8. Image titled Shape a Surfboard Step 8
    The resin: Choose between epoxy and polyester.
    • The polyester is cheaper but not as strong and with polyester it's easier to repair your board.
    • epoxy: very strong, you can use it with extruded polystyrene, but it's more expensive and to repair your board is very complicate. It can turn yellow over time.
  9. Image titled Shape a Surfboard Step 9
    The shape: If choosing a roughly pre-shaped, polyurethane blank, pick the blank and rocker that is the closest to your desired measurements. The less foam you shape off, the stronger your board will be, the less work you will have to do, and the less errors you will make.If you choose to buy a blank a shape(with all its measurements can be chosen from the Clark Foam catalogue and copied onto your polystyrene block foam - this is the hard, cheap way.If you want your own measurements, take your jigsaw and cut your blank as you want. It's a lot of work but if you are patient and motivated you should do it without any problems!

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Categories: Surfing