Fresh project for a newcomer

General Discussion
1

Hello,

I’m new to surfing and surfboard construction and after some research I’m about to embark on an exciting project of building my own surfboard. I have a 6’4’’ Al Merrick Flyer model (PU) that i would like to recreate using local materials (shipping costs for pre-shaped blanks in Europe are prohibiting). Goal is to practice using the cheapest materials i can get to produce a usable surfboard.

 

I’ve contacted several EPS suppliers in Athens to get samples/prices and have a feel for the material that I’m going to work on so here are my first questions

 

1. What range of EPS densities are being used for surfboards ?

I can get from 7 kg/m3 (0.3 lb/in3) to 30 kg/m3 (1.1 lb/in3) or even beyond that after placing an order with a local supplier

2. Do surfing conditions or final shape affect the density that I should chose?

e.g. Average surf in Greece are slow and waist to head waves. Does the bead change in different density? e.g the nose of  the flyer is very thin, can this be achieved with EPS without having material breaking away?

3. Bending the foam or shaping it from a block?

Assuming that i can get some cheap power tools what would be the best option working for the first time with EPS?

 

Thanks in advance

2

EPS for surfboards usually starts at around 1.5lb is a good starting point if you’re going to use a standard fiberglass laminate. 2 and 2.5 are my preference but to your second point, 1.5+/- would be sufficient for your wave-type. Shape it from a block. Bending is the type of thing that requires considerably more tools and materials. Get foam, slice it in half, put in a stringer, laminate with epoxy, surf, repeat.

Good luck!