Hollow Wood Surfboard

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Project by Bags posted 01-10-2013 10:42 PM 3526 views 3 times favorited 16 comments Add to Favorites Watch

My son graduated from law school so I made hiim a surfboard as a present. He was a long time beach life guard and surfer in Bethany Beach DE. Some information on the board:

o the frame of the board is made from 6mm Okoume plywood rescued from a boat yard dumpster in Annapolis MD
o The skin of the board is 1/8 inch redwood rescued as 2×4’s from a fence in Bowie MD
o The Rails are made from 6mm Okoume plywood and sheets of cork
o The green design is a celtic weave that includes the heads of the mascots of the two schools he graduated from – University of Maryland (BA) & Catholic University in DC (JD)
o The finished board is 6’ 8 tall and weighs approximately 19 pounds, which is substantially heavier than a foam board but they say it provides more bouyancy than a foam board and will last a life time.
o There is an air valve inserted in the top front of the board to allow the board to “breath” when it is out of the water. If the board is left in the hot sun without letting the air escape, the hot expanded air would eventually “burst” the board.
o I actually made three boards and used one as a “sacrificial” board – to learn each process as I progressed through each stage.

I found the most difficult part of the build was applying the fiberglass and epoxy finish. I had never used the finish before and it was difficult to get the deep mirror finish that boards are known for. I worried about sanding through the fiberglass.

16 comments so far

View Jamie Speirs's profile

Jamie Speirs

4168 posts in 2942 days

#1 posted 01-10-2013 10:49 PM

That is a nice board
Design build finish are all great
It has a professorial look

-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View Mario's profile


181 posts in 3482 days

#2 posted 01-11-2013 12:10 AM

That´s one radically cool looking board, awesome dude!

View tyvekboy's profile


1783 posts in 3099 days

#3 posted 01-11-2013 01:20 AM

Very nice project. I have a weakness for water toys.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View crashn's profile


528 posts in 2551 days

#4 posted 01-11-2013 02:02 AM

Next, the bar!

-- Crashn - the only thing I make more of than sawdust is mistakes

View widdle's profile


2069 posts in 3085 days

#5 posted 01-11-2013 05:45 AM

Kid should be STOKEd…Right on…

View HalDougherty's profile


1820 posts in 3323 days

#6 posted 01-11-2013 12:49 PM

Great project! I’m impressed with your work.

-- Hal, Tennessee

View ChrisK's profile


1983 posts in 3167 days

#7 posted 01-11-2013 01:04 PM

This project is on my bucket list. I want to use it to learn glassing the plywood foe a future boat. Great job!

-- Chris K

View Fishinbo's profile


11362 posts in 2261 days

#8 posted 01-11-2013 02:40 PM

Awesome surfboard! Love the design and the finish turned out great.


View merle's profile


99 posts in 3210 days

#9 posted 01-11-2013 02:48 PM

i dont see a fin!?

-- merle

View staryder's profile


174 posts in 2125 days

#10 posted 01-11-2013 02:49 PM

Very nice project and wonderful build. Did you design it from the ground up or use purchased plans?

-- Rick.... Fort Worth, Texas

View Bags's profile


39 posts in 3597 days

#11 posted 01-11-2013 03:49 PM

Merie – the board has a glassed on fin – it just so happens not to be in any of the posted photos. If I did it again I wouldn’t glass on the fin but use removable fins. It is so much easier to transport a board (shipping) or storing a board that does not have a fin on it and you can quickly change the performance of the board.Going into this, I really didn’t know anything about surfboards.

Staryder – I got the basic “How to’s” off of the internet and then tried to build a board that was the exact shape of one of my son’s foam boards.

View BigAl98's profile


169 posts in 3125 days

#12 posted 01-11-2013 08:32 PM

You did a great job…as always job prep is everything…and you did it twice! Wow! Also, its very touching to see a father make such a great gift for his son.


-- Al,New Jersey -To thine own self be true

View GerardoArg1's profile


980 posts in 2080 days

#13 posted 01-11-2013 09:23 PM

Wonderfull. What a nice work!!!

-- Disfruta tu trabajo (enjoy your work) (Bandera, Argentina)

View cracknpop's profile


300 posts in 2435 days

#14 posted 01-11-2013 11:35 PM

Very cool. Thanks for sharing (and inspiring)

-- Rick - I know I am not perfect, but I will keep pressing on toward the goal of becoming all I am called to be.

View Jorge G.'s profile

Jorge G.

1537 posts in 2561 days

#15 posted 01-11-2013 11:38 PM

I am not a surfer, but men, that sure is pretty….it is almost a shame it is going to get used… :-)

-- To surrender a dream leaves life as it is — and not as it could be.

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