Sketch the shape of the surfboard.
Create a 3D model with Rhino.
Draw skeleton as inner construction, similar to a fish spine with ribs.
Sketch cut-outs in the ribs so that the air can circulate later in the board.
Raw holes for the plug-in system in the ribs and spine.
To fix the inner construction on the base plate, the central line is marked on the base plate and glued along the marking of the skeleton. For this purpose, the underside of the inner construction was coated with glue and pressed onto the base plate using clamps. In addition to the usual clamps, huge clamps, from an old slatted frame and threaded rods, were build and tightened with nuts.
The outward strips are glued to the side of the base plate along the ribs. A total of three pieces per side are covering the strongest curve before the top plate is fixed.
Before the board is closed with the cover plate, reinforcements for the hardware have to be installed inside the board.
The wooden blocks are flushed with the construction. Therefore the wood has to be sanded round after the installation.
The rear is reinforced with a wooden block so that the fish shape can be carved out. The use of the huge clamps from becomes even clearer when gluing the cover plate to the skeleton, as it has to be pressed against the curves of the ribs.
Who has the technical skills can create a flow mode for the design and the shape of the model. We compared the experiences with other models on the internet. If you need help, there are Fab Labs in nearly every town. There you can laser cut and get support.
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