Board Construction.

As surfing evolves so to must the equipment we use.  Short boards are at the fore front of this due to the world of pro surfing pushing the boundaries everything needs to be lighter,  stronger and faster than before.  As new ideas and materials are used all boards progress.  Here is some info on the basics.  Any advise needed e-mail us or call..NEW IN EXPS SUPER LIGHT SUPER STRONG BLANKS. CALL FOR INFO                                                           

          

  Polyester Polyurethane

This is the classic system of making a surfboard.  We buy the basic piece of polyurethane foam, which already has the wooden stringer fitted down the centre.  The ‘blank’ is now shaped to the size and dimensions required and then sprayed with the colours requested. 

The shaped blank is now ready for laminating.  Glass cloth is applied to the top and bottom of the board and then saturated with polyester resin.  Fin and leash plugs are then fitted before the board is sanded and finished. 

Polyester is the easiest resin to use because a catalyst initiates the hardening process;  the polyester resins have been blended to provide a clear and hard outer structure. 

The advantages of this construction system are that the boards have a second to none cosmetic finish with good clarity,  the boards are light and strong, and easy to repair.

         

  Epoxy Polyurethane

These boards are made in a similar fashion to the polyester boards but epoxy resin is used instead of polyester resin.

Epoxy resin was originally formulated for use in the fabrication of light structures in aeronautical and marine use.  Epoxy resin is ‘set off’ by mixing with a hardener and accelerating with heat.  The result is a lighter and stronger structure.  By using polyurethane blanks the boards are still relatively easy to repair. 

Cosmetically there is little to choose  between epoxy and polyester.  Due to the higher cost of the resin and the more complicated curing system  boards in this construction are a little dearer than their polyester equivalent.  

          

  Epoxy Sandwich

This is a construction system that was developed in the aeronautical industry and has been applied to many products from rockets to Formula One racing cars.

We have been using this system for the last 20 years in  the manufacture of high performance windsurfers.  By the use of vacuum we are able to apply a high-density outer ‘shell’ to lower density light internal EPS core.  The result is the ultimate high strength low weight outer shell.

We have discovered new materials and techniques to enable use to make these boards with a ‘custom’  look.  To have a custom shaped sandwich board is a totally new concept for surfers and we think that you will appreciate the performance benefits, Big weight savings and a solid build.

Sandwich construction is complex and the materials are more expensive hence the higher price.  We recommend you repair the board only with epoxy resin.