Every wanted to be a beach bum but couldn't afford the tools of the trade? It's not too hard to build light weight, sturdy boards out of Insulation!
What you will need:
Pink Polystrene Boards from Home Depot, Menaards etc. approx. $15 for 4'x8'x2"
4 oz fiber glass. (enough to cover the board) approx. $3 per yard.
Polyurethane Resin $70 per gallon!
Polyurethane Glue approx. $8
Ply Wood (Just use what you have in the garage.)
Lots of sandpaper. 150-60 grit
Masking Tape
Approximately 3 days to kill.
How to do it:
Glue the Polystyrene Boards together to form the proper thickness (if needed)
Cut plywood forms to the profile of the board and nail to the sides of the stack of polystyrene.
Cut the polystyrene into the shape of the plywood forms. This is the hard part. You can build a hot wire cutter out of wire and a car battery but I'm not going to be responsible for you blowing up so just use a long saw or cut it in sections.
Make a stencil out of folder paper and cut the outline of the board.
Sand the heck out of it until you are satisfied with the lines. (60 grit) Even sand the flat spots. This helps the resin stick.
Mask the lower edge of the board with tape.
Put on some long sleeves and gloves and cut the fiber glass to fit over the top of the board.
Mix the resin per instructions and pour over the fiber glass. "Paint" the resin evenly over the fiberglass removing any wrinkles as you go.
Allow to dry. Flip board over and repeat!
Sand the board AGAIN with 150 grit and you are ready to paint it with whatever you like.
Cut out holes for fin boxes, mast boxes, foot holds etc. and glue them in. Optionally do this before glassing for added strength.
Your first board may not look too professional but that is the whole point.
