All you homemade EPS blank makers out there.

I’ve shaped a few clark blanks, and I still get into all sorts of trouble shaping from time to time, Rail profile, rocker profile, bottom contour, etc. Rumor say it take 1000’s of boards to become really proficient, There might be truth in that statement

My question is: How in the world are you getting decent shapes, when you haven’t even perfected shaping the Clark foam blank.(or maybe you have) . I mean something that is 95% pro quality. Clark gives you all the profiles, and it’s still easy to screw up. I’d like to see some close up pictures of the EPS’ers

I walk by the Home Depot foam all the time…I look at it, pick it up, think about all the work it would take, then laugh at myself for even thinking about it, and walk away. So my question stands, asides from being lightweight, are you shaping magical boards from the Home Depot.

Show me your boards!!

Bert & Greg’s boards don’t count.

-Jay

It’s just a different material, shaping process is the same as pu, but it’s safer for the Earth and cheaper for the shaper.

my two cents… cause my first eps board snapped in 30seconds, next one will be stronger!

Flavio

Well,

my shaping is s**t at best. Still, my slightly asymetrical EPS longboard works and it’s way less twisted then the one they have at display at the local surfshop for sale at about US$900(I bet if I stop by now, they’ve sold it).

I’m really surprised that the boards I’ve made have surfed as well as they do…

regards,

Håvard

I was wondering when someone would bring this up…way more difficult doing it this way. I cheat…I “borrow” rocker profiles from boards that I like ,make a rocker template, shape the rocker into the blank…then outline …yada …yada. I was getting EPS blanks from an East coast distributor…but now with enough rocker profiles…I can adjust/play with those I have to make what I want or need. Definitely a garage shaper…I have made magic boards for myself…though I doubt someone else would consider them as such,who knows. My boards work better for me than what I used to buy. I agree though…seems like with clark(never shaped one…) you have a real good head start. Don’t have time to post any pics…if you PM me your email addy I’ll send a few to you and if you think them worthy…LOL… you can post 'em. Have fun…

Hey Jay,

I relied heavily on the Surfboard Design & construction pdf - it gives rail band measurments. I marked em lightly on my EPS blank after cutting out the template shape with a very soft pencil (#1 EPS is very soft, spongy, and bumpy). Then using my 2 ft sanding board (a piece of 3/4" plywood with 36 grit glued to it) walked the blank as you would with a planer being very careful to gring it down to the lines. I did 1 “band” at a time & other bands overlap the first bands - you’ll hopefully see what I mean if you look at the pdf.

My biggest fear was screwing up the rails - I think I got lucky with my first board… It came out pretty good. What I did not have that I will make sure of the next time is side lights! I used overhead lights & you really can’t see the little bumps, ridges, etc.

-jay

Jay,

I know we will never equal the crack glue-up team at Clark in our backyards and garages, so…

Check out Segway Composites, they have a series of Greg Loehr rocker profiles available.

segwaycomposites.com (Ken Ebert)

The proceeding was a cleverly designed info-post for my new friends, viva la revolution!

ps Come on up to Cerritos College any Tues-Thursday night, we’re shaping eps, dude!

resinhead…

If you were at the Cerritos Surfboard Forum, you saw Greg Loehr shape a board from one of the EPS blanks we are making. I have been working with Greg and cutting rocker templates based on his design. Greg will take a rocker template, and make “sets” off of that template, where everything from a 6’0" up to an 8’0" will have the same rocker and design.

I am cutting the blanks from “B” bead EPS foam, and will make anything up to an 18 foot paddleboard. If you would like a different rocker template, you can submit the template in paper form, and I will make your specific rocker blank.

I have just started to make Greg’s Parabolic Stringer blanks, but have it in a limited production at this time. They take quite a bit of time to build, and I need to streamline the process.

I am based in So. Cal. and am in the process of getting a shipment materials and shippers lined up. If your in the area, you can contact me and come out to the shop.

As for the home made (Home Depot) blanks… Have fun with it! You are building your own creation, and you should do what works for you. If I can help by building your blank, I am more than happy to do so.

You can check out the site at Segway Composites.com, or give me a call.

Good Luck!

Ken

hey Jay, i’m kinda new to Swaylocks, and I have seen this design and construction pdf mentioned a couple times in the last few days but i can’t seem to find it in the resources, if it’s possible could you hook me up with a link. thanks

as for shaping from eps compared to clark, i have only done a couple boards with xps and eps but i think they are not too much different, i think the secret is to have a preshaped rocker template before you glue it in and then meticulous measuring at each step, take your time and don’t be in a hurry. i have messed up a couple boards by just trying to get them done so i could surf them.

cheers

Well. Mea culpa time.

I don’t want to post any close-up photos of my work :slight_smile:

The shapes aren’t that hard to get into the 90% range. I stop early with the power tools & go long on arm strength - surforms & big sanding blocks for fairing. Even the 2# is easier to fair by sanding than PU foam is.

And then I cover most of 'em up with a sandwich skin anyway. Hides out all the small bumps.

I can only ever find in in a Forum (archive) search - tried the link out & it works:

http://jfmill.home.comcast.net/swaylocks/Surfboard_Design_and_Construction_1977.pdf

Hope it helps… Hope I was the “Jay” you were referring to as there appears to be 2 of us on this thread :>

You can hotwire to very close tolerance, cuts out a lot of the ‘shaping’, Covering with balsa certainly removes the need to sand with anything less than 60 grit.

Ken

is your website down?

and how do you get pricing on Greg’s blanks and the parabolics?

Here in Hawaii I’ve been using Jim Richardson’s molded stuff with alot of success.

Pretty much can crank out a board in 2-3 days without alot of shaping…

Resinhead…

Using HD/Lowes EPS is pretty easy especially if you have a well lit shop and tools, which I don’t. So I have to shape in the bright Ewa sun on a sloping driveway, with racks too high using a belt sander hooked up to a dryvac… lots of fun…

I find a belt sander with 36-50-80 grit to work pretty well but I hear planers are nice as well if you can use them correctly… Not like that “Dirty Jobs” guy on TV last night…

Like some others I “imprint” my base rockers from some standards like a merrick(5.5"x2.5") or a parmenter etc and work from there. If you are gluing up multiple sheets and use a binder like a strip of carbon fiber or slat of wood like bamboo veneer, then the glued up pieces will hold the rocker forever… You can adjust from there with your slicer and dicer what ever you use. It’s alot easier than trying to bend and glue your pieces to a stringer like most do. I use that industrial stretch wrap to hold the foam to the board for a day till the epoxy or gorilla glue dries.

It’s difficult to mow floppy 1lb so you need an entire solid base to rest the blank on like the board you “borrowed” the rocker from or a piece of wood on your racks like LeeD suggested some time ago. Even MikeJ and Chipfish’s ironing board shaping racks are a good idea for soft EPS. One secret we’ve learned is to visualize and shape your bottom contour onto the bottom flat piece of EPS on a table before you glue it up to the top piece to snag a rocker. Then all you have to do is shave down the deck to your desired thickness and do your rail bands. Chop the mass down with short strokes blend and finish your shape with long light fast strokes no matter what cutting tool you have in your hand. But everyone knows this anyway…

My bro and I are getting somewhat proficient at this sahping business but we’d be awesome if we had nice cool room with side lighting, good stands and a planer with a cord/vac jig like I saw in the pics from Keith’s event… hell we’ve been doing most of our finish work with a 2’ long 2x4 with a cutup 36 grit beltsander belt stapled to it and a bunch of drywall screens.

Other tools that help…

an adjustable rocker measuring stick

a set of calipers

A see thru vertical/horizontal measuring plastic

One,

Weird. I was just going to post this link and I think they are the same blanks you just referred to.

http://www.surflight.com/eps.html

Yea They’re sold out for now till they get their next shipment…

I bought somew of the last 1.8lbrs. Saturday

Jeff had actually re-rockered one into a 6’10" high performance shortboard he was going cut in Eric’s machine but I bought it to make me wooden 6’8" flyer ala Bert Burger with the pulled in tail bump…

Charlie bought 6 of the 1.4lbr’s to try out

I already made test boards of the 1.4 and 1.8 with no shaping involved just cleaned them up and lammed them as 7’6" fun boards… One out of balsa one out of Mahogany and Birch

The blanks are stringerless and are preshaped in a Jeff Johnston funboard shape so they are pre-rockered, bottoms done in a single to double with slight vee and rails cut. If you like the shape you just have to clean off the mold marks. Or you can re-shape them into anything you want that fits within the mold provided…

Since they are molded the denisty of the beads are tight and the surface skin is sealed if you don’t sand it troo much so it won’t suck resin like regular EPS and you don’t have to spackle it. Real easy to work with and real expensive for Jim and Jeff to make the mold $20,000 or more… Someone on the mainland is pouring them. Jeff is trying to convince Jim to switch to 1.5 versus 1.8 density…

My brother and I spent about an hour talking to Jeff Johnston at their factory while we were waiting for Jim to show up and Jeff showed and told us alot of neat stuff. Kind of eye opening stuff related to the business of surfboard manufacturing and the use of new technologies… Bottomline it’s all about sales and whos’ buying boards not to what Jeff or Jim might want…

Jeff is one of the parties responsible for Aviso and he showed and explained to us the whole project. The stuff’s been out and tested hard on the north shore over the last year and a half… Jeff’s real high energy and into epoxy and making light boards and they test everything even Greg’s stuff… Some are durable like Aviso (they start like $1500 for 6’2") and some are for safety/performance like the surflights. But they do hundreds of polys too to pay the bills. It’s amazing the amount if things they’ve got going on at the same time but you can see they battle being fought between making money to pay the bills and feed the family versus the mad scientist engineering track to create something better. It’s a difficult balance to maintain… But Bert and Greg there’s more going on with Epoxy EPS than anyone will admit too if that’s consolation for the “other” thread.

Funny part is that Jeff and Jim interested in this wood veneer stuff us grems are doing and may give that a go as well just to try it. We showed one of the completed balsa lammed 7’6" blanks and they were impressed witht he weight and strength. Jim even laughed when he saw Hicksy’s wininng Swaylocks logo on the tail by the rear fin…

Right now they are just glassing their EPS in various methods to get the lightest and strongest boards they can build for Andy to use… Yup trying to get Andy to compete on 4lb epoxied EPS with no one knowing about it… You go figure that one blue versus red…

Sorry for going off again… But it was a real eye opening experience again…

Oh by the way, we stopped over at the hollow wood board factory up the street and got blown away…

You would not believe what those guys are doing for the super rich…

The 10’-12’ Brewer wall hangers fullguns start at $15,000- $20,000 but are just absolute works of art.

A woodworkers dream…

They also make rideables but most of their work are the wall hangers…

The 1/4" intricate inlay work of Koa, Mango, Burled Walnut, Milo, etc is out of this world and they can actually make one of these in a week… It helps to have a complete woodworking factory occupying two warehouses full of wood and machines…

Their main business is custom hardwood inlay doors for the Multi-million dollar houses in Kahala, the big island or Hawaii Loa Ridge (like my bosses house) they usually take a board with them when they deliver the doors and usually sell them on the spot since it’s chump change for the folks living in these houses… I can’t imagine the cost of their doors…

What we saw blows everything in wood I’ve ever seen on sways to the next universe and then some… Would even make Roy want to crawl into a hole and hide with what he’s making…Yea and sorry Paul but these guys seem like they are in another league…

It’s amazing what’s really going on out there when you get a chance to peel back the onion…

Hey Mark,

just wondering and this probably sounds a bit thick, if you veneer an EPS blank with balsa are you safe to glass with poly? I’m guessing that this would be OK, if not where the hell do you get reasonably priced Epoxy in this country?

Jase (MMM)

Aloha neighbor One… Thanks for the tech update on the local scene over there. I never can get any information on current events there, from over here. I haven’t been to O’ahu for quite a long time. I hear you about the expense of r&d though. Summer is typically pretty dead for surf/ surfboards, and I’ve been eking all summer while I’ve been schooling on the RR program. Been making HD blanks and everything. Right now, I can hardly wait for the season to start so I can get busy again. I’m looking forward to shaping whatever kind of blanks the people want, I don’t mind. I’m stoked to be able to do it at all! It’s been a long, hot summer, I hope all you brothers over there are staying cool. Aloha…RH

Quote:

Jay,

I know we will never equal the crack glue-up team at Clark in our backyards and garages, so…

Check out Segway Composites, they have a series of Greg Loehr rocker profiles available.

segwaycomposites.com (Ken Ebert)

The proceeding was a cleverly designed info-post for my new friends, viva la revolution!

ps Come on up to Cerritos College any Tues-Thursday night, we’re shaping eps, dude!

I hate you.

-doug (the jealous one)

Jay:

Block of EPS

Rocker templates and Hotwire

Split the blank and glueup w/stringers of PVC or Wood

Shape with grit drum and sanding blocks

Seal with epoxy/filler

Color with acrylics

Laminate and Hotcoat with R/R Epoxy

Fin System then sand and gloss with R/R Epoxy

Homemade is always magic! If you can’t go for a billet of foam just glue up the H/Depot sheets. Heck, I did some of the first ones in 4" thick Dow XPS blue styrofoam, not ideal but I got used to using epoxy and the hotwire and only had to buy one 4"x24x96 piece of foam at a time @ 1/3 the cost of a Clark blank. Do it!

Tom S.

aloha resinhead,

check out my thread…fishboard layup help.

i’m using 1lb density eps foam. The custom block started at 14 feet long x 27 inch wide x 24 inch deep. hot wired down to what you see in my shaping room (my shaping room is only 16ft long x 8 ft wide x 9’10" tall) .



Great stuff here… so what is the ideal weight of foam for EPS? The 1.# stuff feels way way to soft to me. I was at Star Foam here in Vista and I checked out what they had to offer. To me 2# felt and looked to be the best for building boards.