I shaped a 4’10 for my son and a 5’6 for me last August. Finally got around to glassing them last month. 4’10 is a twin. Sprayed/sealed the blanks with acrylic paint and acrylic Pledge (Future) floor sealer.
Glassed three layers of cloth onto the rails (no pics). Traced the outline onto mylar sheet and layed up a layer of 3 oz S cloth on a table. Rolled out bubbles with epoxy roller. Allowed to cure.
Vacuumed the hardened s cloth skin onto the bottom with another layer of 3 oz s in between, just as I would do with a veneer. The point was to not have to sand the bottom or deck. Ran into major problems:
The skin was so pliable, that it formed to the wrinkles in the release cloth and bag. Decided to use a hard plastic sheet against the deck skin to keep it from wrinkling. No wrinkles, but got some spots where the hard sheet couldn’t conform to the curves in the deck and got some spots with more resin than others. Ended up having to sand the deck, anyway. Hotcoated and hand-sanded the rails. Left the bottom with the wrinkles. Finished product (deck):
8-yr-old son is stoked on it (first hard board). He went under a white wash (can’t duck dive, yet), and it hit him in the mouth, cutting his lip. Didn’t deter his happiness, though.
My 5’6 coming up next.