Construction Process
A background in wooden boat building and airplane wing design led to the development of our construction process (patent pending). We use extruded styrene foam (xps) for the rails and skeleton, and either marine grade plywood, or strips of various woods, to form the bottom and deck of the board.
The use of foam to determine the shape of the board allows for a design freedom similar to shaping an entirely foam blank, and considerably decreases the finished weight compared to an all wood board. The result is a board that is beautiful, unique, lightweight, and custom made to surf. Additionally, our boards are often lighter than all foam boards.
Wood skins are glued to the skeleton in an adjustable mold to get bottom contours just right. Foam rails are glued on and shaped. Boards are fiberglassed with epoxy resin and either e or s glass. We offer fins glassed on, or fin boxes.
We use an xps foam skeleton and add fiberglass to center or perimeter stringers. The inside wood for the deck and bottom are fiberglassed (with the weight and type of glass dependent on the wood type, thickness, and desired flex of the board).
Constructing rails out of foam greatly reduces building time, enables us to fully customize each board, and shaves off considerable weight.
