Etude de cas Nucle-Art

How to make a surfboard

• Since when do we surf & Where did it start  

Surfing began in the pacific and was discovered by the british James Cook on the great island of Hawaii. Since the 15th century surfing was a common practice in this island, it allowed tribal chiefs to challenge the sea and its elements on large wooden boards and prove their superiority. During the colonisation this practice was forbidden because it was practised almost naked and was considered an act of depravity. It was not until 1900 that Jack London, the olympic swimming champion, published numerous articles on this unknown sport, which then spread mainly to Australia, California and France.

• How many surfers around the world

35M mainly in Oceania and United states. But now very present along the west european coast.

• How much does a surfboard cost ? How much does it cost to build ?

Between 500$ and 700$ for a beginner → quite as expensive as skiing

Around 300$ when you do it by yourself

steps to build a surfboard

• Draw some plans (paper or shape3d) : imagine the stringer and the outline

In order to realise the board of your dreams it is important to think about it and to follow a number of steps so that it can last in time. First of all you have to draw the board you would like by representing the stringer (the profile of the board) and then the outline (the view from above). In order to make these drawings we can use software such as shape 3D which allows us to model the board in 3 dimensions. This software is quite easy to use and proposes to draw your board from several other already saved models.

• Use appropriate materials (fiberglass, Polyurethane, expanded polystyrene or epoxy resin → the most environmental friendly))

In order to make your board, you need to buy 3 raw materials: the foam core, the fiberglass cloth and the resin. About the fiberglass cloth, 3 layers can be applied on top of the board and 2 on the underside to make it stronger. The number of these layers will affect the weight of the board, so it is up to the surfer to judge whether he prefers a stronger or lighter board.

• The shape

Now it’s time to transform the foam block by making the lines imagined at the beginning appear. First we have to form the rocker or profile of the board with the help of templates that we will put on the foam, and with a hot wire we will cut the foam following the templates. Then with a saw we cut the outline of the board following the line drawn on the foam with a felt pen. Then we continue with the sanding in order to give the foam its final shape.

• The watertightness and solidity of the board

To continue the building, you’ll have to apply fiberglass all around the board in order to solidify the structure and to gain weight on your different stratifications. This layer really needs to wrap up all the board to be as efficient as possible. Fiberglass is really appreciated by surfers because on top of it’s a very solid material, it also is light and environmentally clean.

The fiberglass gives strength to the board, but it doesn’t protect it against humidity.

That’s why after the application of fiberglass, you’ll have to apply a succession of resin layers : this part is called the stratification. It consists of wrapping the board with a specific resin which can be polyester resin or epoxy resin. The Polyester one is cheaper but Epoxy is tending to impose itself as it’s the most efficient one even with a very thin layer. The principle is simple. You have to apply the resin on a side of the board and then on the other side once the first is dry. For example you begin with the top. First scotch the periphery and then apply a mixture made of resin and a few other substances on the flat part. Once the resin is dry, do the same thing on the other side. You can use a brush to spread out the resin efficiently and to do a good uniformisation. A few layers are necessary so you’ll have to repeat the process several times on each side.