Hollow Wooden Surfboard CNC Cut Kits

1. The ribs and spar are cut from high quality mahogany plywood.   You 
simply snap out the parts from the backing and get ready to build the 
frame just like an airplane wing.

2. The parts fit together to form a strong, lightweight frame.  The 
numbered ribs are slipped into notches in the spar with the matching 
number.  Ribs are spaced about every 6 inches for maximum strength.  

Now the wood planking can be added.  The middle strip is critical and is 
the first one placed.  The other wood strips are added two at a time and 
the glue allowed to completely dry before the next two strips are installed.

Commonly available plastic wrapping film is stretched into a string and 
used to tie the planks in place while the glue dries.  It is very strong 
and eliminates the need for dozens of expensive clamps.  The plastic 
string is looped around and under the ribs so that it holds the planks 
to the ribs as well as to each other.  This system results in strong, 
gap-free joints.  Detailed pictures in the manual that comes with each 
kit show the process.

3. Once all the planks have been glued to the deck the frame is extremely 
rigid and can be released from the building table.  The sticks that were 
hot glued to the ribs are simply snapped off.  A longboard sanding block 
is used to remove any glue spots.  Once the ribs are all flush, the bottom 
planks can be installed.  You have the option of installing one plank at a 
time (as was done on the deck) or gluing the planks together to install it 
as a single piece.  You can even cover the bottom with plywood.

Blocks are added at the tail where the fin box  and leash cup will be 
placed.  The blocks can be made from balsa or other light woods.  
Scrap foam from a discarded surfboard can also be used. Once the 
bottom is installed and glassed, a router is used to make the cavities for 
the fin box.  If a glass-on fin system is used the blocks aren’t needed.

The bottom planks are installed and rough trimmed to match the deck. 
This board was built with hardwood planks on the deck and balsa 
planks on the bottom.  This combination makes for a very strong yet 
light board.

4. Then the edges of are carefully sanded until the deck and bottom are 
even with the wood strips on the end of each rib.  This ensures that a 
perfect outside contour is achieved.  

The rails are built up in layers using balsa.  You can also alternate 
dark and light wood strips to make layered pattern.  The strips are 
bent as far as they will go without breaking then they are cut off 
square. Wood pieces are cut and fitted around the tight curve.  The 
manual supplied with the kits shows all the steps in detail.

Photos and text supplied by Wood Surfboard Supply.