Hollow Wood How-To Video and Kits

Hi Folks,

Grain Surfboards is starting production of the first “Hollow Wood How-to” video in January. We’ll be keeping a couple of cameras in the shop to record the process of the next few boards in detail (including tips, tricks and trade secrets).

Example Chapters will cover:

  • Board design and selection

  • Techniques for reverse engineering (acquiring key dimensions from an existing board)

  • Employing Computer Aided Design

  • Tools, safety, and supplies

  • Wood Types/qualities and Lumber Selection

  • Detailed Construction process of Keel/Rocker, Frames, Re-sawing/Gluing Planks, Railing out.

  • Shaping

  • Glassing

If you interested in purchasing the DVD, please send an email to to reserve a copy. We’re also taking suggestions through this email so, now’s your chance to help make the video most effective.

Rich and Mike are also hard at work developing CNC routered kits. So be on the look out for those.

Rich and Mike are also hard at work developing CNC routered kits. So be on the look out for those.

The new generation of craftsman… it seems boat building might make more money, but sharing the stoke w/ surfing might keep you Yankees content through the frozen months. Thanks for showing the dinosaurs how to keep it real. “The Underground Lives”

Seasons Greetings



Thats cool. Get a classic redwood longboard kit with instructions on how to do it. That’s pretty novel. You could build one. Then several boards later, get the same one you got, and since you know a little more than your first one, you could tweak it and shape it.

I like the reverse engineering how to. Pull a shape from something you like, fins, rocker etc . . . and translate it to your hollow wood board.

Good idea I think. I’d definatly be intrested in the video.

When you talk about Hallow Wood boards, are you talking Jensen hallow? or Chambered, which could be called hallow, but not really.

I would like extream detail in the deck and hull gluing method.

Are you going to provide exact mesaurments of all of the peices?

Long or short board?

Dose the DVD come with a paper planshape template so that measuremnts stay true?

Projected cost for a varation of boards?

*It would not be A bad idea to get Paul in the movie if you are using the Jensen method.

All of this looks pretty crazy, fix that would you?http://www.swaylocks.com/…?post=230914;#230914

Still trying to figure out how you use this thing…

Wow! Thanks so much for the feedback (both here and in the many emails I’ve gotten). This is EXACTLY what I was hoping for - suggestions BEFORE we begin filming from folks who would eventually be the viewers . This will surely make the DVD most useful. Please - keep’m coming!

To clarify up front, this is NOT the Jensen method. Those interested in that approach should buy his CD “How to build a hollow surfboard” I hear great things about it.

In response to some of your emails:

A (very) little background:

Mike (the other builder at GSB) and I live in Maine. For many years we talked about shaping out own boards. When the talk turned toward using wood, we immediatley drew on our boat experiences, and in particular New England boat-building techniques to try building our own. To make a long story short, we found some time tested techniques used to build lobster boats to work extremely well, and some not so well. So we’ve modified our ways (a classic example of boat-building evolution) to make the process most efficient for our smaller “watercraft.”

There are fundamental differences in the GSB approach. It’s all about the WOOD. We really like the idea of tradition and are commited to using the absolute minimum of glass and epoxy. In fact, we’re really trying to develp a glass-free, and maybe even an epoxy-free method too (the very first board we made, called Eve, was both glass and epoxy free, albeit heavy). We depend on the wood for strength and exploit it’s natural bending qualities to “fair out” our curves (a sometimes tricky thing to do with 1/4" frame members).

Simplicity is also a key factor for us. We want people to succeed in building thier own board, not get bogged down building gluing forms or having to buy expensive tools (maybe it’s a Maine thing). When you build a GSB board, all the work is done on-the-board - just like a boat. The keel is laid first, frames go on keel, planks on frames, rails on planks. No bending is done “off” the board. in effect the board IS the gluing form. Don’t get me wrong, it’s still challenging for woodworking newbies, and you will need a few key tools, but you won’t have to be Norm Abrams, or an off-duty cabinet maker to do it.

On a green note, environmental concerns are a high priority (in fact my personal highest). We’re developing relationships with sustainable wood producers (such as Vermont Family Forests) And strongly encourage (more like require) builders to commit to planting at least ten trees for every board they build. I suggest planting some of them in places that really need them - like the “islands” in the middle of Wal-Mart parking lots. Sorry about this little tree-hugger digresion.

While I’m at, let me just mention my view of this community. There are people out there with lots of money, but not a lot of time, or desire to build thier own board. But they still want to have a beautiful, functional, and unique board. We serve those types by building pricey boards for them. I venture to guess, not many of those types are reading this right now. But then there is you - the Swaylockeans who we see more as our peers. We’re willing to share ideas with you (in both directions) simply because we share your stoke.

And yes Rhino they are hollow…built hollow, not chambered.

PS…A pack of cedar seeds will come with each kit.

Interesting that you are also pursuing the glass-free construction of HWs… I’m all by meself here in the far north(finland) and have been playing about with the same concept. My first board was supposed to be ready at this time but … its abit behind schedule. I did get the frame(stringer+crosspieces+inner rails) out of the jig just yesterday. My methods follow Jensens methods up to a point but I have excluded the carbon fibers and glassfibers , replacing them with aircraft quality birch plywood ; 0.8mm-2.5mm… ok so it may get to be on the heavy side- time will tell, I will hopefully know more after next july… thats when I think I will be able to test them out (and hopefully learn to surf as well :wink: )

I have also employed CNC and Cad design in my board(s) as well some were redundant, some were completely useless, but there were the few innovations that have worked so far, most with jigs and tools. Cad design has been useful in the overall design of the board.

My approach to this is partially “newbie” to surfing (ie. dont know how to, so far have spent only 12 days in portugal trying to learn…) , joiner/cabinet maker with some experience with wooden built experimental aircraft + plenty of free time at my hands.

I will try to post some pictures later somewhere, regarding the parts that are not the Jensen method.

All the best to all, this is kinda interesting hobby sofar.

Sounds sweet. Would love to see those photos.

Glass/Epoxy free is going to be tricky… me thinks. I’m all for it on a personal use board. But given current methods, I’d be hesitant to sell it to a non-wood -butcher. So until a really trustworthy method evolves, we’ll have to settle for minimizing the synthetics.

Sounds like this should be the next mission of us wooden board builders. Inventing a glass/epoxy free wooden board that weighs less than cement. I’m game - and I’ve got some ideas - anyone else? Up for the challenge?

PS. Get any good waves over there?

PPS. Might as well make it a Bonzer.

Thanks.

The original surfboards were made of hardwood and were sealed with oil, right?

Why wouldn’t that work for a glass/epoxy free hallow?

Has anyone used teak for hallow surfboards yet? The natural oilyness of the wood could be perfect for glass/epoxy free boards.

Cheers,

-Austin

*How much will you guys be charging for the video?

Quote:

Glass/Epoxy free is going to be tricky… me thinks. I’m all for it on a personal use board. But given current methods, I’d be hesitant to sell it to a non-wood -butcher. So until a really trustworthy method evolves, we’ll have to settle for minimizing the synthetics.

Richie, As I said before the durability of a glass free epoxied board is, in my experience, better than a board with glass. I say this after subjecting my own boards to the roughest treatment imaginable for many years on end. . . leaving them on roofracks or out in the grass through the wettest winters and driest summers, and thrashing the boards on a daily basis. In my opinion glass is just an unneccessary bummer except with very soft timber like Balsa. I have built more than 60 wooden boards over a ten year period, so I know my onions, so to speak. It’s good to see how fast you are becoming an expert, but on the subject of durability there is no substitute for experience. . . . how long have you been at the wooden board game? What I am saying is that glass free epoxied boards have already proven to be trustworthy. As for epoxy, I’m all for it. Roy :slight_smile:

Rich,

When you talk about a glass/epoxy free board, are you talking about a board that just dose not use glass like Roy mentioned above? Or are you talking about a board that uses no ammount of resin what so ever? I’m a little confused.

Hey guys,

Thanks for your responses.

The epoxy-free hollow wood is just a thought experiment. Impossible?…maybe. But what better place than Swaylocks to dream and scheme? Maybe http://www.nomorefoam.com

Austin – If I’m not mistaken, most very early boards we’re solid. In which case, leaks don’t pose a “catastrophic” problem. As for teak, maybe… It’s pretty heavy though. It think it weighs about twice as much as the cedar we currently use (~23 lbs/cf vs. ~44). So to maintain our current weights, we’d have to use about half as much wood – maybe tough.

Roy -

I’m really glad that your boards are glass-free and can still withstand the rigors of racks, grass, and seasons. But as I’ve said before, “our” approach, which tries to balance lots of factors (weight, durability, ease of construction, performance and our own aesthetics), I assume is, different from yours.

So when I speak of glass/epoxy free, I mean with respect to “our” method – or a method yet to be developed. Which is where I was hoping to steer this thread (maybe we should start a new one).

As for experience, do you really want me to answer that? If so, read my bio or send me an email. Otherwise, our boards speak to that.

The reason I find glass/epoxy hard to simply abandon (for “our” method) is because once a board ships, it alone represents us. We stake our reputations on the factors listed above. And what works for my personal board does not necessarily BEST serve my customers - yes, customers - a potentially different breed than us.

Well Rich, your ‘Bio’ is certainly entertaining, but it doesn’t answer the question, which is:

How many wooden boards have you built, when did you start building wooden boards, and how long have have you been riding wooden boards ?

I have noticed, as I am sure you have, that customers sometimes ask these questions. . . . it’s part of your credentials, so don’t be shy, tell us about it please !

Regards,

Roy Stewart

:slight_smile:

PS Rich, does the following quote mean to say that your thread is intended for the discussion of methods pertaining only to hollow wooden board methods used or developed by grain surfboards ?

Quote:

So when I speak of glass/epoxy free, I mean with respect to “our” method – or a method yet to be developed. Which is where I was hoping to steer this thread (maybe we should start a new one).

:slight_smile:

Hi Roy, I’m really sorry if i struck a nerve. Now, can we please keep the discussion productive? Thanks,

Not at all Richie my friend,

Just wondering about your board building history, after all you are setting yourself up as a board building expert, so it is possibly relevant in terms of the board durability issue.

I am not one of those “you have to have done it for X number of years” types, let’s just hear it though mate, your board building history, after all, you tell us on your website all about eating raw goat kidney and nearly being shipwrecked so you are obviously an open kind of guy, and Swaylock’s is a sharing kind of place, so don’t be shy, let’ hear it ! . . . . what would you say if a customer asked you about your board building history ?

My other question was regarding this thread. . . is it intended ONLY for Grain surfboards “How to” and promotions, or is it open to anyone doing HWS “How to” videos ??

Here’s a small video showing a bit of feral plank milling . . . . . some recycled Poplar TG&V being re sawn into 1/4 inch thick planks for the deck and bottom of a new 10’8" ‘Thrusterbuster’ pintailed foilboard.

http://www.olosurfer.com/movie_theatre.html

Regards,

Roy :slight_smile:

Regarding this thread, of course it’s not limited to discussions of GSb (as demonstrated by the postng of your fine home video). In fact, as a place for free discussion, I hope it’s a place where one can share (or withhold) anything they wish (so long as its not defamatory).

This has been fun - now move on - I have.

By the way, National Public Radio is doing a story on GSb. It will have lots information. I’ll send you a link when it airs.

Hi Richie,

Invoking the 5th amendment then ? :wink:

Regarding that video clip, I must point out that it is NOT a fine home video, it is a FERAL PRO video :wink:

What are you guys building right now, anything unusual ?

Regards,

Roy

BTW, in regard to customers, I have sold forty or so boards over the years, so I meet them now and then!

:slight_smile:

Regarding the 5th - your half right - nothing incriminating about it.

With regards to leaks, so what would you say is the feedback you get from your customers (in general). No leaks? And if so where? At joints? Which ones? What would you say is the weakest point - the strongest?

We’re not building anything unusual. Just (2) 6’4 fish (1) 6’8 fish and (4) 9’ longboards. How about you?

Quote:

Grain Surfboards is starting production of the first “Hollow Wood How-to” video…

If you wouldn’t mind, please not name it “Hollow Wood How To”…

It’s so very similar to what I’ve been calling my “How To” cd - “How To Build A Hollowsurfboard”…

You say that you have your own process, hopefully you’ll find your own original name, a name that is unmistakably YOU

That’s what I’ve done…

I don’t think the possible confusion would be good for either of us or potential buyers…

Stay original

Paul

Quote:

[b]How many wooden boards have you built, when did you start building wooden boards, and how long have have you been riding wooden boards ?..Roy

[/b]Here’s a partial answer…

Posted on NoMoreFoam.com

Quote:

Hey, This is Mike from Grain Surfboards. My friend Rich and I have been building hollow cedar boards here in York Maine for 6 months…

Paul, what would you like them to name it? I mean, come on, hollow wood surfboards have been made for so many years that it’s pretty much a generic term. I can’t think of any other terms to describe them than hollow, wood, and surfboard.