First off, let me confess that I have never successfully caught a wave in my life, and I'm 47 years old. The few times I have tried surfing, I felt that I was way to heavy for the type of board I was using. With that said, I traded a few emails with Chad and decided to make a 10' longboard by enlarging Chad's templates by 10%. Over the last three days I have cut the patterns from plywood (15/32 plywood for the spine and 5mm for the ribs), and glued up the skeleton of the surfboard. Here's a few pics of my progress thus far.
I was initially concerned about a curve in the spine, but later realized that I can straighten this out when I glue the skeleton to the bottom deck. I also borrowed a large box of heavy spring binder clips from work that I'm going to try to use to secure the rail assembly while it's gluing. I appreciate any pointers any of you might have.
I also had a little problem with the tops or bottoms of some of the small ribs extending past the spine and not being flush even though I cut everything exactly to the pattern. I should have asked instead of making an assumption and gluing it all together. After the fact I got Chad's advice and sanded down these high spots with the frame assembled and glued. I did my best to smooth out the ribs so there aren't really drastic divots. I first tried doing this using a cheap-o planer a bought at Harbor Freight, but quickly got frustrated and switched to an abrasive disc on my grinder. It isn't exactly precision work, but I'm hoping it will smooth out when I shape the decks?
Post by juliangibraltar on Jun 23, 2014 4:51:02 GMT -5
Hi Bobby, I had this problem also and ended up spending a lot of time sanding....not to perfection either. What I found was that it was a better fit to place the top strips one by one as this made sure that the contact to the rails was better (than if I'd glued the top deck together and then placed in on the skeleton as one piece). After that the highs and lows of course appeared in the deck but with 6mm thick strips there was enough to do some heavy sanding to make the top smooth.......this does mean a lot of sanding and as someone else said somewhere on the forum, the better the start the easier the finish but that's easier said than done!!!!
Ah the bane of the woodworker. It'll never be as perfect as you envision it and you will always know where the tiny imperfections are. Everyone else will just be impressed with your skills. You will spend a lot of time sanding. Just accept it, and you'll be ok I use a random orbital sander with hook and loop discs for large areas and one of those multi tools with the cutter/sander attachments for smaller stuff.
Frame looks pretty good from the pics! Keep up the good work and keep us posted!
Welcome to the forum!! Sand sand sand, my belt sander with 100 grit worked well for shaping. I also used a cordless power planer made by Ridgid it also worked very well. Taking a little extra time in the beginning will pay off in the end. Keep the pictures coming.