This design style descended from the 1930s Tom Blake paddle-boarding method, which favors a central stringer, with individually shaped transverse ribs covered with a skin, and lastly, rails which are then shaped.
This skeleton is subsequently sheathed with thick wood strips, forming a fast hollow board with better flex properties and giving you a sick ride.
Wood Surfboard Kit Frame
Once you shape it out, you must seal it with resin and fiberglass (or bamboo). How cool is that, putting together your own board eco style just like the OG surfers of the past?
It's a great project, and there is nothing like surfing your own personally-made board.
Video
Prancha de Surf - O Sapo from Roland Schär on Vimeo.
4-Steps
Get the full guide here.
FAQ
1. Question: What do the kits contain? Do they have everything I need?
Answer: The regular kits consist of the ribs and spar pieces that make up the frame. They also include a full instruction manual that covers every step of the build in detail. You will need wood for the outside planking, glue, fiberglass, and shop supplies like sandpaper. You can buy or build a fin to be glassed on or mounted in a fin box.
2. Question: What is the best kind of wood to use?
Answer: Recycled lumber is the eco-friendly, cost practical choice. Reclaimed lumber such as redwood and cedar are excellent wood choices as they are often already light and dry. If you are going for a lightweight board, you will want to use softwoods like redwood, cedar, pine, paulownia, or balsa. If you don't care about weight, go for exotic hardwoods. We have used mahogany, ebony, oak, and others. The hardwoods are beautiful and healthy but heavy.
3. Question: What's in an export kit?
Answer: An Export Kit contains the same parts as the regular kit, but the spar has been cut into approximately 24" pieces. These pieces are glued together using the backing blocks with the equipment; for most kits, that means 3 or 4 glue joints. We have spoken to many users, and they say the extra work is no problem, and there is no loss of strength. We can ship an export kit anywhere in the world using US Postal Service First Class mail.
4. Question: Do I have to glass the board, or can I just varnish it?
Answer: If you are only going to hang the board on a wall, simply varnishing it is adequate. You should always glass a board that is going to be used. Not only to seal the water out but to give the board the strength it needs.
5. Question: What's a vent for? Is my board going to explode without one?
Answer: Explode? No. But if you leave it in the hot sun, it can puff up and weaken the inside glue joints. It can also delaminate
6. Question: Where do I buy wood for the planking?
Answer: Lumber suppliers and home improvement stores are the obvious answer. Most builders love the challenge of finding the perfect wood for their board, and they will search through pallets of wood to find the perfect pieces. We have found beautiful heart redwood being sold for planter edging in the garden department of Home Depot. Lumber suppliers like Austin Hardwoods will even cut a custom kit for you. The assembly manual lists a lot of good sources and even tells how you can get free wood.
7. Question: Is the assembly a printed copy?
Answer: No, it's a PDF file you can display on any computer. It gets emailed to you when your order is processed so you can start planning before your kit even arrives. You need Adobe Acrobat Reader software, available for free download at www.adobe.com, but chances are it's already on your computer.
8. Question: I've never glassed a board, is it hard?
Answer: The assembly manual outlines the process, but if you are not sure, watch some surfboard glassing videos on www.youtube.com. This will help you see glassed, and many tell us it's not as expensive as they thought it would be.
9. Question: What kind of resin do you use?
Answer: We think epoxy has an edge over polyester on wood surfboards. Some builders have reported that Polyester resin will delaminate from certain kinds of wood. We have had good results with both polyester and epoxy, but epoxy is lighter, easier to use, easier to clean up, and has virtually no smell. We tell the best epoxy and where to get it in the assembly manual.
10. Question: How do I choose the board that's right for me?
Answer: You choose a wood surfboard the same way you would choose a foam board. If you want to cruise and maybe get some nose riding in, you want one of our longboards. If you like to go wild and really shred, one of the fish will do the job. If you want something in between the long and shortboards, the Mini Mal is perfect. Then there are the Stand Up Paddleboards that will let you cruise standing up in style. The bottom line is that if a certain kind of foam board works for you, its wood counterpart will work the same.
11. Question: How much woodworking ability do I need, and what tools?
Answer: This is not the easiest project you will ever try, but it's probably not as hard as you think. If you follow the detailed instruction manual, you will be fine. As for tools, a table or band saw is a must. Also, a belt sander and block plane are necessary. As for a power-thickness planer, if you have one, that's great. Many builders have made deals with cabinet shops or local school wood shops to plane the wood for them.
12. Question: Can the kits be modified?
Answer: You bet! That's why we call the Chameleon the Chameleon. If you build it according to plan, it's an egg. It can be modified in many ways to make it faster and more maneuverable. The kits can also be narrowed somewhat if desired. The instruction manual has a complete section on how to modify a board.
Shapes
5'6" or 9' ECO Chamber Mini Simmons
This board won "Best of Show" in the "Most Sustainable Surfboard" category at The Boardroom International Surf Expo 2012.
It's a planing hull design with parallel rails, twin keel fins, and it literally flies through the water.
Kits are now available for both the 5'6" Mini Simmons and the 9'0" full-size Simmons style board. Both built using "eco chamber" build technology!
See this post for directions on how the eco chamber system works.
In the order menu pick Mini Chambered 5'6" or 9' to Check out.
5'6" FAST LUCY FISH
"The Fast Lucy" got her name because she's fast and loose!
She's great in summer surf she'll still crank on head- high days.
If you are making the transition from long-board to short board this is the way to go.
Any number of fins from one to five works.
- Length: 5’ 6”
- Width: 21 3/4 in.
- Nose: 18 1/4 in.
- Tail: 18 1/4 in.
- Thickness: 2 1/4 in.
This Kit contains a complete frame consisting of ribs and main spar (stringer) and an electronic assembly manual covering every step.
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You will need wood for the outside planking, fiberglass, glue, sandpaper and standard tools to complete the kit.
5'6" FUGU FISH
"The Fugu Fish" is a high performance fish designed in conjunction with Justin Grover of Liquid Lifestyles in Australia.
Justin loved the Fast Lucy that he built but wanted more performance.
What he and Brad came up with is a lightweight rocket with a dual channeled bottom.
The performance is like a short-board but you still have the benefits of a fish.
- Length: 5' 6"
- Width: 20"
- Nose: 14"
- Tail: 16 1/2"
- Thickness: 2 1/2"
This Kit contains a complete frame consisting of ribs and main spar (stringer) and an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and standard tools to complete the kit.
6' MID FISH
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"The Mudfish" falls right between the Fast Lucy and Kingfish.
Like its two cousins its still fast, loose and fun – just a little longer to accommodate the bigger riders. I think 6' is a good length for a fish, most I ride are between 5'10" and 6'. It's nice to have a little extra board to paddle into waves and get through flat sections
- Length: 6’ 0”
- Width: 24 1/4 in.
- Nose: 20 1/4 in.
- Tail: 20 1/4 in
- Thickness:2 1/2 in.
This Kit contains a complete frame consisting of ribs and main spar (stringer) and an electronic assembly manual covering every step.
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You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
6'6" KINGFISH
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"The Kingfish" is our largest WSS fish. It was designed for bigger surfers who still like to rip but has been putting down too many cervesas this year.
Still fast, loose and fun (like those chicks you used to date in high school).
This one is big and fat like your . . . well, why continue.
Like the other fish you can build it with any fin combination.
- Length: 6’ 6”
- Width: 25 3/4 in.
- Nose: 21 1/2 in.
- Tail: 21 1/2 in.
- Thickness: 2 3/4 in.
This Kit contains a complete frame consisting of ribs and main spar (stringer) and an electronic assembly manual covering every step.
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You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
6'8" The Toad
"The Toad" with its multi channel bottom profile, is a challenge to build but worth the effort. The channels hold a line and let you crank turns you won't do on any other wood board. The bottom is planked in the usual way but the contoured ribs let you make perfect channels
- Length: 6' 8"
- Width: 25 1/4"
- Nose: 20"
- Tail: 18"
- Thickness: 3"
This Kit contains a complete frame consisting of ribs and main spar (stringer) and an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
7' Driftwood
"The 7'0" Driftwood" This is the real hot rod of the Driftwood series. It has the speed and agility you expect from a performance hybrid when its built to plan but it can be shortened to 6'6" for an even more radical profile.
Choose the fin setup that's best for your style and harden the rails for snappy turns and an edges that hold tight.
- Length: 7’
- Width; 22"
- Nose: 18 3/4"
- Tail: 16"
- Thickness: 3"
This Kit contains a complete frame consisting of ribs and main spar (stringer) and an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
7'6" Chameleon
The 7'6" Chameleon is a high performance surfboard, well, let's say it's a long-board that performs like a short-board. When it's built according to plan it's an egg that lets you make the most of any size surf. But you can put your own spin on it and make it much more, sharpen the nose and tail for more speed or maneuverability.
- Length: 7’6"
- Width: 23 1/2"
- Nose: 17 1/4"
- Tail: 15 1/2"
- Thickness: 2 3/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
8' Driftwood
"The 8'0" Driftwood" 8-foot performance hybrid. This board has enough volume to float riders in the 180 pound neighborhood easily. Te driftwood is a long-board that thinks its a short-board. Its the nose and tail have been narrowed giving sleek lines and awesome speed and maneuverability. You'll be cranking turns you never thought possible on a long-board.
- Length: 8’ 0”
- Width: 22"
- Nose: 15 3/4"
- Tail: 16"
- Thickness: 3"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
8'0" Mini Mal
Classic mini Malibu style long-board with its roots in the 60s. Build it with modern rail profile for a great performer or stick with the traditional 50/50 rails for that sweet paddling nostalgic feel.
The Mini Mal is a perfect starter board for the younger surfers but is also fun for the experienced rider and makes a great transitional board.
- Length: 8’ 0”
- Width: 24"
- Nose: 21 3/4"
- Tail: 15 1/4"
- Thickness: 2 3/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
8'1" Driftwood Sr.
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"The 8'1" Driftwood Sr." 8-foot performance hybrid that we widened a little for better flotation and stability. Designed for riders in the 200+ pound area.
Same sleek lines and incredible speed and maneuverability as the Driftwood, just floats more. You'll be cranking turns you never thought possible on a long-board.
- Length: 8’ 1”
- Width: 24 3/4"
- Nose: 21 1/4"
- Tail: 18 1/2"
- Thickness: 3 1/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
8'6" Chameleon
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The 8'6" Chameleon is a high performance surfboard, well, let's say it's a long-board that performs like a short-board. When it's built according to plan it's an egg that lets you make the most of any size surf. But you can put your own spin on it and make it much more, sharpen the nose and tail for more speed or maneuverability.
- Length: 8’6"
- Width: 23 1/2"
- Nose: 17 1/4"
- Tail: 15 1/2"
- Thickness: 2 3/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
8'11" Clearwood South Beach
Designed with carving in mind this is a board you can really have fun on! Fun board? You bet!
With the right fin set up this board will improve your surfing like you won't believe! We recommend this board be set up with the Hanalei "thumb" T2 series fin.
This series of fin creates an amazing "pop" out of the turns and we have found nothing like it for positive control while maintaining a fun and loose feel.
- Length: 8’11
- Width: 29 1/2"
- Thickness: 4 1/4"
This Clearwood Kit contains a complete frame consisting of ribs and main spar (stringer). Our innovative "rocker tab" system eliminates the need for a rocker table and assures an accurate rocker profile with every kit.
We encourage the use of plantation grown paulownia wood for "skinning" these boards. With the help of high quality marine plywood for the framework and a paulownia wood skin, a hollow wood board should last many years if not a lifetime!
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
9'0" The Robert August
The Robert August is the board that Robert August uses himself around the world during his surf travels.
This board can do it all from powerful carving 360s off the tail to great nose rides. This board features a moderate width nose with a nose concave underneath for extra lift while nose riding.
60/40 rails let it will paddle nicely and still crank turns at will.
- Length: 9’ 0”
- Width: 24"
- Nose: 21 3/4"
- Tail: 15 1/4"
- Thickness: 2 3/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
9'0" Cruiser
The 9'0" Cruiser is a slightly shortened and trimmed down version of the Original Cruiser. We took 6" off the length and narrowed the nose 1/4".
You'll get even more performance out of this classic long-board shape.
Its still got just enough rocker to be forgiving on late takeoffs but still has speed down the line. Be prepared to spend some serious nose time with this board.
- Length: 9’ 0”
- Width: 22 1/4"
- Nose: 18 1/4"
- Tail: 16"
- Thickness: 3 1/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
9'6" The Robert August
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The Robert August is the board that Robert August uses himself around the world during his surf travels. This board can do it all from powerful carving 360s off the tail to great nose rides.
This board features a moderate width nose with a nose concave underneath for extra lift while nose riding.
60/40 rails let it will paddle nicely and still crank turns at will.
- Length: 9’6”
- Width: 24"
- Nose: 21 3/4"
- Tail: 15 1/4"
- Thickness: 2 3/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
9'6" Cruiser
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The original Curiser was inspired by the great long-boards of the 60s Build it with retro 50-50 rails for that sweet turns on a dime and hugs a wave tight.
Its got just enough rocker to be forgiving on late takeoffs but still has speed down the line.
Be prepared to spend some serious nose time with this board.
- Length: 9’ 6”
- Width: 22 1/2"
- Nose: 18 1/4"
- Tail: 16"
- Thickness: 3 1/4"
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
10' Gordo
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"The Gordo" is our original "Big Boy Board". . But just because it's big doesn't mean it's clumsy.
The rails have been pinched slightly to give it agility and performance.
- Length: 10’ 0”
- Width: 23 3/4"
- Nose: 19 1/2"
- Tail: 15"
- Thickness: 3 3/8 in.
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
10'10" Clearwood Checto
This "old school" single fin longboard style surf SUP has a very progressive rocker profile and was designed to surf!
Many boards around this length are designed as "all around" boards. This is definitely not the case with the "CHETCO".
Although you CAN paddle the "CHETCO" around your local estuary or lake, this board really is most at home in the surf and is a great longboard style ride.
- Length: 10' 10"
- Width: 29"
- Thickness: 3 3/4"
This Clearwood Kit contains a complete frame consisting of ribs and main spar (stringer). Our innovative "rocker tab" system eliminates the need for a rocker table and assures an accurate rocker profile with every kit.
We encourage the use of plantation grown paulownia wood for "skinning" these boards. With the use of high quality marine plywood for the framework and a paulownia wood skin, a hollow wood board should last many many years if not a lifetime!
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
11' Malco SUP
"The Malco 11 foot SUP was designed by Malcolm Schweizer in St. Thomas, Virgin Islands. It has a little concave in the nose and a slight "V" in the tail.
Plus the new rib design lets you build the rails two different ways (built up solid rails or wood strip hollow rails.
- Length: 11’ 0”
- Width: 30 3/4"
- Nose: 23 1/2"
- Tail: 19"
- Thickness: 4 1/4" in.
A SUP needs to have good hull speed for "flat-out" paddling but needs to have the ability to plane for surfing. The Malco was designed to achieve both these goals.
You can paddle fast for long distances, but still be able to surf once you are there easily. It is designed with paddling in mind - its not just a big surfboard that comes with a paddle.
This Kit contains a complete frame consisting of ribs and main spar (stringer) as well as an electronic assembly manual covering every step.
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
12' Orca or Lake Superior SUP
The "Orca" was designed for stand up paddling which requires maximum flotation and stability. It's at home on a lake or in the surf.
It has a flat bottom and enough rocker that it is at home paddling into a wave.
- Length: 12"
- Width: 30 1/4"
- Nose: 19 3/4"
- Tail: 17 3/4"
- Thickness: 4 3/4"
The "Lake Superior" was designed for stand up paddling in lakes and calm water. It has less rocker than its cousin "The Orca" because it doesn't have to contend with waves.
- Length: 12"
- Width: 30 1/4"
- Nose: 19 3/4"
- Tail: 17 3/4"
- Thickness: 4 3/4"
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You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
12'6" Clearwood Umpqua
The Umpqua is a fun race board or a speedy touring board. In general the 12'6" class of board is intended for lighter paddlers so if you are over about 170 pounds, then our 14' "CASCADE" is more appropriate for you.
If you "skin" the "UMPQUA" with 1/4" paulownia wood and glass it with one layer of 4oz cloth the finished weight should be about 26 pounds.
- Length: 12' 6"
- Width: 27"
- Thickness: 6" at nose
This Clearwood Kit contains a complete frame consisting of ribs and main spar (stringer). Our innovative "rocker tab" system eliminates the need for a rocker table and assures an accurate rocker profile with every kit.
We encourage the use of plantation grown paulownia wood for "skinning" these boards. With the use of high quality marine plywood for the framework and a paulownia wood skin, a hollow wood board should last many many years if not a lifetime!
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
14' Clearwood Cascade
The "CASCADE" for bigger paddlers that need more volume in a board.
This should be another great performer for those who want to go racing a wood board or just have fun touring a fast and beautiful wood SUP.
- Length: 14'
- Width: 27"
- Thickness: 6"+ thick at nose
This Clearwood Kit contains a complete frame consisting of ribs and main spar (stringer). Our innovative "rocker tab" system eliminates the need for a rocker table and assures an accurate rocker profile with every kit.
We encourage the use of plantation grown paulownia wood for "skinning" these boards. With the use of high quality marine plywood for the framework and a paulownia wood skin, a hollow wood board should last many many years if not a lifetime!
You will need wood for the outside planking, fiberglass, glue, sandpaper and common tools to complete the kit.
15' & 15' 7" Paddle Cat
The "Paddle Cat" is our SUPER STABLE stand-up paddle board that allows you to bring along a friend or just chill while you take in the naked girls screaming at you along the beach.
Here are some thing you can do with this rad cat:
- Paddle the bay of lake while thinking about your life
- Add a motor and show your friends that you can still drive
- Add a sail and good to Hawaii and surf the Pipeline
- Add a more relaxed and umbrella with lots of cold beer.
- Also great for fishing or nude sun bathing.
The paddle Cat includes the pieces you need to build the two hulls shown in the picture. The builder must supply the plywood for the platform and dog.
The Paddle 200 has a float capacity of 200 lbs, and the Paddle 300 has a float capacity of 350 lbs.
