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How to Rebuild a Surfboard From a Blank

Surfboard blanks are forms made from either polystyrene or polyurethane foam. Rebuilding a surfboard from a blank can be done by using your old surfboard. You can complete this task by first obtaining the dimensions of your existing board and then making a template. A template is an outline that is used to form the shape of the new surfboard. You can make the template for a surfboard repair using a long roll of paper.

Things You'll Need

Roll of paper
Pencil
Surfboard blank
Masking tape
Handsaw
400-grit sandpaper
Fiberglass matting
Fiberglass resin
Brush

Instructions

- 1
  Roll out a length of paper out on the floor. Set your existing surfboard flat on the paper. Trace its shape by using a pencil to make an outline. Cut off this length of paper with the scissors.
- 2
  Roll out another length of paper. Place the existing surfboard on its side and trace the shape. Cut around the outline of the surfboard on each piece of paper to make a template.
- 3
  Set the blank to use for the surfboard on a set of saw horses.
- 4
  Place the template in Step 1 on top of the blank. Secure the template to the blank by using the masking tape. Cut around the template with a handsaw to form the shape of the surfboard.
- 5
  Secure the template in Step 2 on one side of the blank and cut around the template. Repeat this step on the other side of the blank.
- 6
  Sand the cut surfaces of the surfboard with a 400-grit sandpaper. Round the edges to form the rails for the surfboard.
- 7
  Cover the surface of the surfboard with fiberglass matting. Mix the fiberglass resin using a catalyst and apply it to the matting with the brush. Allow the resin to dry for at least four hours.

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