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The Surf Source

Build Your Surfboard

The Surf Source has all of the tools and materials you need to build your Surfboard, SUP or Kiteboard.
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Foam surfboard blanks

Modern surfboard blanks are made from two types of foam: polyurethane and polystyrene. Most boards are made of polyurethane foam blanks using resin. When repairing your board, it’s important to use the proper resin since failing to do so can increase damage. Don’t, for example, repair epoxy boards with polyester resin.

Laminating

After a foam blank is shaped, it’s laminated. This process combines both resin and fiberglass cloth to seal the foam and create strength. Most modern surfboards are laminated with four- and six-ounce fiberglass cloth using laminating resin (polyester resin without the addition of sanding solution) or epoxy resin.

First, the cloth is cut to size and laid over the foam. Then resin is applied with a squeegee to evenly distribute and saturate the resin in the cloth. The process should be repeated on the bottom, carefully wrapping the rails to blend over each other. This is standard procedure for both polyester and epoxy resin using fiberglass cloth.

Finishing

Once the board is laminated and the fin plugs are put in, it’s time for finishing. This refers to how the surface of the board appears. There are two basic finishes: sanded or gloss. Both begin with a final coat of resin for finish sanding. Polyester boards require sanding resin, which contains a liquid wax additive that coats the surface for easy sanding. (Note: Laminating resin should never be used for finishing; the surface will remain tacky.) Epoxy resin is used for both laminating and finishing.

The final coat of resin must be sanded, usually with a foam-backed sanding wheel and a medium-grit sandpaper. This step evens the surface of the board. A sanded gloss coat is the base for either a sanded or polish finish. Sanded finishes are then wet-sanded with a fine grit and sprayed with lacquer. Gloss finishes require additional wet-sanding and polishing.