The next part in the process is to start to build up your rails. I cut up the pallets into 6mm strips and then start gluing. I like to make my rails two strips, 12mm, thick so I have some leeway when shaping the rails. This process takes time as each strip takes 6 hours or so to set. You also need lots of clamps. I find this the easiest way to bend the rails neatly. There are other ways to do this so whatever suits your needs.
next I tidy up my frames and cut some holes. Often people think this is to lighten the board which it can do. But more important is to ensure air flow throughout the board. Because my boards are hollow, the air inside expands when it's hot and contracts when cold. Hence the need for a vent. I've also made a bottom for the board which as you see in the photos is like a sheet, glued and clamped and left for 24hrs. Then I attach the frame to the bottom.
The next part for me is to design what I'm after on the computer using the shaping program AKU shaper. I already have a bank of shapes that I use and will change to suit what I'm building. From AKU I then send the file to the program Hollow Wooden board maker, which converts the shape into ribs and spine. Then I print these out and stick them onto marine ply and cut out using a jig saw. I then clean them up with a planer and file. This is the point where I will put concaves or vee into the board.
To build aboard from wooden pallets, the first step involves finding a wooden pallet. There are many types. For this board I found a pallet that was a lot lighter than most of the others. Sometimes I chose pallets based on weight other times based on wood grains or a really rustic and worn down look.
Next it's time to take apart the pallet and denail it. This can be tricky and can result in wood splitting and breaking.
Because the panels are often different thickness I then cut them into even strips, in this case 5cm wide. Then cut these strips down to a thickness of 6mm.
Lastly any pieces that are spilt or have imperfections I cut into 6mm wide strips that I will use to build the rails on my board. From this one pallet I will have almost enough wood to make a board. This will be a thruster, 6'3
All of this took 3 hours. Next part will involve the frame and ribs.
Surfers Healing is an awesome organisation run by Izzy Paskowitz, that takes kids with autism surfing. The stoke they create is amazing to watch and be a part of. If you haven't heard of them look them up. Each year they run a charity auction at the Ritz Carlton in Laguna to help them continue they're brilliant work.
This year I donated a hollow wooden surfboard that was made from scrap wooden pallets, picked up from the side of the road. The board is s 5'10 fish made using the hollow wooden surfboard method. The board turned out really well with a rustic feel to it. The board weighs about 7kg which is heavy for a surfboard but is completely surfable. The weight of a wooden surfboard can vary greatly depending on the woods used, and the method of the build. This board was built with longevity in mind, hence it being heavier.
The art reflects all the positive energy bouncing around on these days. It shows a surfer with a child on his back having what Surfers Healing call One Perfect Day.