Neal Bahram's Wood Fish!

1. Your Name: Neal Bahrman

2. Your Brand name: n/a

3. How did you hear about us? Yahoo search

4. How was your initial experience at Foam E-Z? Good!

5. Why did you want to build your own board? The last board I bought was made by guys in a sweat shop in China! I said that’s it, I’m making my own from now on!

6. Shape of finished board? 6’8” retro fish

7. Size of finished board: Length 6’8” Width 22 ½” Thickness 3”

8. What blank did you use? Hollow wooden surfboard – strips over framework

9. How was your board building experience? Great! Except the final gloss coat – still wrestling with that!

10. Did you use videos, books, web, other? Yes

11. What videos, books, web, other did you use? Tree2Sea forum, swaylocks, surfersteve.com

12. Do you recommend these resources? yes

13. What do you wish you knew going into this project? That Merton’s sb112 takes so freakin long to dry!!!

14. What would you recommend to someone else for their first time? Do your homework first, then Go for it!

15. What tools did you find most useful? Clamps clamps and more clamps! Belt Sander!

16. Where did you run into trouble? Final gloss coat

17. What kind of fin system did you use and why? FCS – it's what I had on my other board.

18. Did you glass the board and what was that experience like? Yes. It was cool. Turned out nice. But the SB112 resin takes 12-15 hours to set up. That is just WRONG! I don’t like the stuff!

19. Where did you shape and glass your board? In my backyard shed

20. What type of board do you want to make next? Another hollow wooden surfboard retro fish!

1. Your Name: Neal Bahrman

2. Your Brand name: n/a

3. How did you hear about us? Yahoo search

4. How was your initial experience at Foam E-Z? Good!

5. Why did you want to build your own board? The last board I bought was made by guys in a sweat shop in China! I said that’s it, I’m making my own from now on!

6. Shape of finished board? 6’8” retro fish

7. Size of finished board: Length 6’8” Width 22 ½” Thickness 3”

8. What blank did you use? Hollow wooden surfboard – strips over framework

9. How was your board building experience? Great! Except the final gloss coat – still wrestling with that!

10. Did you use videos, books, web, other? Yes

11. What videos, books, web, other did you use? Tree2Sea forum, swaylocks, surfersteve.com

12. Do you recommend these resources? yes

13. What do you wish you knew going into this project? That Merton’s sb112 takes so freakin long to dry!!!

14. What would you recommend to someone else for their first time? Do your homework first, then Go for it!

15. What tools did you find most useful? Clamps clamps and more clamps! Belt Sander!

16. Where did you run into trouble? Final gloss coat

17. What kind of fin system did you use and why? FCS – it's what I had on my other board.

18. Did you glass the board and what was that experience like? Yes. It was cool. Turned out nice. But the SB112 resin takes 12-15 hours to set up. That is just WRONG! I don’t like the stuff!

19. Where did you shape and glass your board? In my backyard shed

20. What type of board do you want to make next? Another hollow wooden surfboard retro fish!

Red Perspective by Dan Howard

1. Your Name: Dan Howard

2. Your Brand name: Red Perspective

3. How did you hear about us? Through my buddy Mark who works for the
shop.

4. How was your initial experience at Foam E-Z? Always been the best.

5. Why did you want to build your own board? Since I first started
surfing I knew I wanted to one day become a shaper. Building and
riding your own board is one of the most rewarding experiences you
can have as a surfer and gives you the ultimate ability to dial in
your equipment. The best part is knowing that whether you build
one board or one-hundred, you have contributed to the amazing
lifestyle that is surfing and have become more than just a consumer.

6. Shape of finished board? Classic log similar to a late 50’s to
early 60’s Velzy pig or Malibu Chip.

7. Size of finished board: Length 9’9” Nose 16 ¾” Width 22
½” Tail 17” Thickness 3 ¼”

8. What blank did you use? US Blanks Green 10’2” B

9. How was your board building experience? Better than ever.

10. Did you use videos, books, web, other? I learned all I know thus
far from years of watching others, talking with shapers and
studying board design. My buddy Mark was the one to finally take
me into the shaping room and helped me through my first board.

11. What videos, books, web, other did you use? I usually just Google
whenever I need info.

12. Do you recommend these resources? There’s a lot to be found on the
web…

13. What do you wish you knew going into this project? Having never
shaped this type of board, I would have liked to know a few more
tricks for shaping more efficiently. Thanks to a close familiarity
with this style log, having ridden many, I eventually ended up
with just what I wanted, but it took me much longer than it should
have.

14. What would you recommend to someone else for their first time? I
feel the most important thing when shaping is to understand how
boards work. If you know what makes a board work you will be able
to figure it out what you need to do to shape the board you want.

15. What tools did you find most useful? A good power planer (Hitachi
in my case), sharp Surform and a padded sanding block are a
must. The E-Z Square for measuring out the template is a gift from god…

16. Where did you run into trouble? I got stuck about half way… I mean
really stuck… figuring out the bottom contours of this board. I
literally had to just stop and take a break to think it over
before I continued. I knew I wanted to give it a lot of belly so
the board would hold back easier in the pocket, but didn’t wan to
make it too slow. Eventually I just threw some MUSE on the stereo
and went and went for it.

17. What kind of fin system did you use and why? I hand-foiled a 9.5”
plywood pivot fin to be glassed on after I had finished shaping
the board. I set the fin 2” from the tail to give plenty of drive
and stability through turns and gave it a moderate rake to keep it
lively.

18. Did you glass the board and what was that experience like? I had
this one expertly glassed next door at Aloha and highly recommend
their work. I have glassed a board, however, and it was a huge
learning experience. I think every shaper should at least know how
to glass a board.

19. Where did you shape your board? I shaped it right out
back in the E-Z Shaping Box.

20. What type of board do you want to make next? I am coming in later
this week to shape a 9’6” classic cruiser for my father. I’m
planning on keeping the template pulled in and trim with a low to
moderate rocker throughout (using a US 9’8” Y).

Anthony Brock's Electric Surfboard Project

The project goal was to design and build an electric motorized surfboard. The electric motor and propeller fit into a standard
longboard fin box. The propeller is in place to replace paddling.
The board will propel itself out to the line-up and into a wave. Once riding a wave, the board uses the forward motion produced from the wave to continue to spin the propeller and produce energy from the electric motor. This energy is stored to recharge the batteries. The board is essentially a miniature wave energy power plant. The board uses a small commercially available electric trolling motor and a 12V 7.2amp-hr battery. Wires run along the deck of the board under the glass next to the stringer from the battery housing back to the motor.

As this board was a prototype there were some problems. It was difficult to keep the battery compartment on the top deck of the board waterproof. It was flooded with water several times. Somehow the motor continued to work even when flooded, but I was shocked a few times when trying to take the battery out of the flooded compartment back on shore. The board itself was huge. It turned out to be overbuilt and did not need to be quite that large. It is a 10'8" x 30" x 5.5" SUP. I first tried the board out at the Santa Ana River jetties just because it was close and I wanted to get it into the water right when it was finished. The board powered through the crashing waves and quickly got me to the line-up, but it was very
difficult to actually ride a wave because of the size of the board.
It does not turn easily and it tends to pearl. I was able to catch a few waves there, but I had much more success at SanO. The problem at SanO, though, was that the seaweed floating around in the water kept getting caught on the propeller.

Work is still being done on this project as a hobby. Future developments will have everything housed in a single attachment that can fit into a standard longboard fin box. This way any longboard can be modified with this device. We won't have to worry about running wired to a battery housing on the top deck anymore. I am also working on incorporating a flow sensor that will detect the speed of the board while riding a wave and adjust the speed of the motor to counteract the drag caused by the motor. A wireless motor controller that you can wear around a wrist is also being developed.

That's a brief overview of the project. If you have any questions feel free to ask.

Neil's Single Fin Eggy!

1. Your Name: Neil

2. Your Brand name: Don’t have one.

3. How did you hear about us? Browsing the web.

4. How was your initial experience at Foam E-Z? It was good…got everything I needed and could afford to build my own board.

5. Why did you want to build your own board? Watched “North Shore” one too many times I guess.

6. Shape of finished board? Single fin Eggy.

7. Size of finished board: Length 5’10” Nose 17” Width 22” Tail 17” Thickness 2 ¾”

8. What blank did you use? US Blanks 6’2” A fish.

9. How was your board building experience? Excellent and time consuming…didn’t use a single power tool all hand planer and sandpaper…built shaping racks with a hand saw and 2 x 4’s too.

10. Did you use videos, books, web, other? All of it.

11. What videos, books, web, other did you use? Shaping 101 and Glassing 101…some different books…swaylocks.com is a lifesaver.

12. Do you recommend these resources? yes

13. What do you wish you knew going into this project? How to glass better.

14. What would you recommend to someone else for their first time? Have fun and don’t worry if it doesn’t turn out perfect Mine is far from perfect, but its so much fun to surf and so rewarding.

15. What tools did you find most useful? Planer, calipers, sand paper.

16. Where did you run into trouble? Glassing…cutting down humidity and keeping a stable temperature.

17. What kind of fin system did you use and why? O fish l single fin box…it was the easiest…get it set…glass over it…sand the cover off...i wanted to make a single fin.

18. Did you glass the board and what was that experience like? I did…it was a little sketchy at first but I got the hang of it…ended up pretty smooth except where the top and bottom overlapped near the rails.

19. Where did you shape and glass your board? Shaped on my back porch and glassed in the break room at my office (don’t tell anyone)…It was the best place I could find where I could really control the temp.

20. What type of board do you want to make next? I was thinking a quad fish but I bought one instead…now I'm thinking SUP.

21. Extra info: Building your own board was so much fun…cant wait to do it again.

Cowan's Greenough Inspired Diamond Tail!

1. Your Name:Jamie cowan

2. Your Brand name: cowan

3. How did you hear about us? Sacred craft

4. How was your initial experience at Foam E-Z? cool

5. Why did you want to build your own board? I have always liked to build cool stuff. I was a hefty 250 when I was looking for a board hard to find at 6’6", 3 inches thick or more. So I got a blank and went for it.

6. Shape of finished board? I made a template off an old Greenough kneeboard

7. Size of finished board: Length 6’6" Nose 15" Width 23" Tail 16"

8. What blank did you use? I think 6’10A fish blank

9. How was your board building experience? Rad, I did it without a planer just the David Plane and floor sanding paper

10. Did you use videos, books, web, other? web

11. What videos, books, web, other did you use? Surfersteve!

12. Do you recommend these resources? ya

13. What would you recommend to someone else for their first time? Lose your fear!

14. What tools did you find most useful? The lights are important to me.

15. Where did you run into trouble? The stands I made kept moving.

16. What kind of fin system did you use and why? Future

17. Did you glass the board and what was that experience like? No, I let Grygera and sons do the first one they gave me a great deal, and did a good job.

18. Where did you shape and glass your board? I shaped it in an empty warehouse.

19. What type of board do you want to make next? I have already done 5. I am going to glass my first board this weekend.

The Bouvier Keel Fish

1. Your Name: Mark Bouvier

2. Your Brand name: None of that nonsense

3. How did you hear about us? I saw your booth at the sacred craft tradeshow.

4. How was your initial experience at Foam E-Z? Great, the crew is very helpful, and full of knowledge.

5. Why did you want to build your own board? It seems as though when you go to the surf shops these days all of the boards are built to be an “every-man’s” board. To me that means they do all the basic things a boards should do, without actually doing anything well. So to find that diversity it’s best to look at your own style of surfing and try to make something that will work well for you as an individual. And if it doesn’t work like you thought, then you’ve learned something new because you’re riding something that isn’t just a basic all-arounder type shape.

6. Shape of finished board? 5’11 Fish. Thick with thin pulled down rails with belly in the belly and "V" in the tail.

7. Size of finished board: Length 5’11 Nose 16 ½ Width 21 ½ Tail 17 Thickness 2 ¾

8. What blank did you use? 6’5 A. I picked this blank so that I could pull the template back a few inches and cut some of the rocker out of the nose giving me a flatter entry rocker.

9. How was your board building experience? Great. I used the E-Z Shaping Box at the shop for the second time. I love the Shaping Box, it’s totally set up, I can get in there, shape, rent whatever tools I don’t have, and then just sweep up and walk out. Way better than having a shaping room in my garage.

10. Did you use videos, books, web, other? I did not. This one came entirely out of my head. Because it was such a funky design, I tried not to pull ideas from other shapers, otherwise it would be that much less unique.

11. Do you recommend these resources? I recommend trying new things with your surfing and board building. It helps you put things in perspective and look at what you love from another point of view.

12. What do you wish you knew going into this project? How to better do a fabric inlay. I get the feeling that my fabric didn’t lam up too well, and am kind of afraid of the board delaminating in the future. But I’ll just deal with that when and if it comes along.

13. What would you recommend to someone else for their first time? Know what you want to shape before you even buy your blank. Know exactly what you want, because if you go into a project like this with an uncertain idea of what you want to end up with, even if you’re just torn between two designs it will never come out quite right.

14. What tools did you find most useful? TAPE!!!! I know I’m getting ahead of myself, but doing a cut-lap on the rail, using tape actually takes just a short time to set up, but saves a lot of time in sanding. Tape is your friend.

15. Where did you run into trouble? This board actually went very smoothly. The only thing that kinda bummed me out was when I built up my hotcoat on the tail so I could get a nice down rail, I built it up too thick, and it cracked. No biggie…it kinda gives it character. But next time I’ll know not to kick it so hot if I’m going to pool it so deep.

16. What kind of fin system did you use? I glassed on a pair of custom keels that I made.

17. Did you glass the board and what was that experience like? I did. It was messy, stinky, and left my patio looking like an abused armadillo dying in a pile of tape, resin covered brushes and fiberglass dust.

18. What supplies were purchased from Foam E-Z? all of them. Everything from the blank to the armadillo! Ok, except the razor blades and the fabric. I got those from JoAnn’s fabric right down the street.

Dan Surfboards 70's Single Fin Hot-Dogger!

1. Your Name: Dan Howard.

2. Your Brand name: I just slapped a big ole DAN on the deck.
3. How did you hear about us? I heard about Foam E-Z through several shapers I have known over the years and was finally put in contact by my buddy Mark who works there.

4. How was your initial experience at Foam E-Z? It was good. There was plenty of inventory to browse through when selecting a blank, including seconds in almost every size, which helped me stay within a tight budget and still build a completely functional board. The staff were all really helpful and knowledgeable, and just seemed genuinely stoked to see me getting into shaping. Having access to a proper shaping bay was hands down the biggest benefit.

5. Why did you want to build your own board? As long as I’ve been surfing (12 years) I have been deeply fascinated by the colorful history of surfboard innovation and design. I love how each and every handcrafted surfboard is completely unique in its own way and the pure creative artistry that goes into that. I’ve been blessed with artistic abilities my entire life and always knew I had it in me to become a successful shaper but never actually tried. Finally I just decided it was time to make it happen. Paddling out for the first time on a board I built was easily my proudest day as a surfer.

6. Shape of finished board? Early 70’s era single fin hot-dogger.

7. Size of finished board: Length 6’4’ Nose 15’ Width 21-1/2” Tail 15” Thickness 2-3/4"

8. What blank did you use? 6’10” A US Blanks (second).

9. How was your board building experience? This was my very first board. I had a fairly basic yet solid knowledge of the board building process and understood the specific mechanics behind different boards and how they will work in different waves.

10. Did you use videos, books, web, other? I had collected a lot of knowledge throughout the years through all kinds of sources, but mostly from listening to and watching other shapers. My buddy Mark from Foam E-Z was there to walk me through the whole process; so I owe most to him.

11. What videos, books, web, other did you use? Just a little bit of web browsing.

12. Do you recommend these resources? I honestly recommend talking with shapers, asking questions and watching anyone who will let you. I’ve sat in and watched Rich Harbour and Tim Stamps shape boards start to finish. They didn’t explain what they were doing and I didn’t bug them with questions, but I learned so much just from watching. If you can have anyone help you out through that first board that’s got to be the best way.

13. What do you wish you knew going into this project? Honestly, I felt about as prepared as I could be. Having an experienced shaper there to help me out filled in all the gaps and gave me the confidence I needed to build the board I really wanted.

14. What would you recommend to someone else for their first time? Pretty much what I said to question 12. Look at every kind of surfboard and learn what it does, how and why… every kind of board. You’ve got to know the mechanics behind surfboards if you’re going to have any chance of building a functional board. Ask and listen. If you can, get help.

15. What tools did you find most useful? The Hitachi power planer is a Godsend and I’ll never shape without one. Other than that, a nice sharp sure-form and a proper sanding block made life nice and easy. Skip the 2x4 and spend the few extra bucks on a proper block and you’ll save sanding time and come out with more even rails.

16. Where did you run into trouble? I was a bit sketched out about shaping my rails with the power planer at first, but after a little demonstration by Mark I realized how useful it was. During the glassing process it was a bit difficult tucking all the rails before the resin gelled and keeping bubbles out of the seams while laminating. We were really conserving resin though, so I’d probably recommend spending a few more bucks to buy some wiggle room. Defiantly don’t try glassing your first board without help. Mark really saved my ass there…

17. What kind of fin system did you use? I fabricated an 8.5” raked single-fin glass-on from a box fin (the base got turned into the leash loop).

18. Did you glass the board and what was that experience like? Yeah, we glassed it in my garage on top of a card table and a cardboard box. As a mentioned for question 12, it was a bit difficult at parts, but not bad as long as you have somebody there who knows what they’re doing. Shaping and glassing the board was even more rewarding. That’s how they had to do it back in the day and it remains a skill I feel every shaper should have. Being able to call yourself not just a shaper but a “board builder” is pretty special these days.

19. What supplies were purchased from Foam E-Z? I picked up the blank and all the glassing materials from Foam E-Z and borrowed the tools from Mark. I plan on purchasing my own set of tools through Foam E-Z for the next board. The selection is quality and the prices seem reasonable.

RadRob's 5'4" Mini-Nose Rider

1. Your Name: RadRob

2. Your Brand name: RadRob's radical surf creations

3. How did you hear about us? I work here (Foam E-Z)

4. How was your initial experience at Foam E-Z? Absolutely amazing!!!!!!!!

5. Why did you want to build your own board? It's a cool experience to ride something you built.

6. Shape of finished board? mini noserider

7. Size of finished board: 5'-4" x 25 ¼" x 2 15/16"

8. What blank did you use? The new 5-10 RP (second)

9. How was your board building experience? It was great.I tried to get a little creative on the glass job this time.

10. Did you use videos, books, web, other? Not so much this time. I couldn't find a board quite like i wanted out there.

11. What videos, books, web, other did you use? I have watched the JC videos as well as the Master series.

12. Do you recommend these resources? For sure.

13. What do you wish you knew going into this project? I feel like I was pretty prepared for this one.

14. What would you recommend to someone else for their first time? Get as much information as possible before you start.

15. What tools did you find most useful? CF planer.Once you get comforterble with a power planer it makes the shaping experience much more enjoyable.

16. Where did you run into trouble? The giant nose concave.

17. What kind of fin system did you use? Glass-On single fin.

18. Did you glass the board and what was that experience like? Of course, the UV resin is awesome.

Bouvier's Bomber!

1. Your Name: Mark Bouvier

2. Your Brand name: No label.

3. How did you hear about us? Originally from a friend.

4. How was your initial experience at Foam E-Z? Great, I remember the first time I came in, the guys were all very helpful in picking out the right blank and letting me know what tools I would need to get started without selling me a bunch of stuff that I wouldn’t need as a first time board builder. One of the best resources now is the shaping box…It’s a fully set up shaping room available for rent. Also available for rent are all the tools necessary to really get a good feel for shaping. It’s a great way to try out the expensive tools (such as the industry standard Hitachi planer) without breaking the bank your first time out.

5. Why did you want to build your own board? I’ve always felt that if you love doing something, you should explore all aspects of whatever it is. Learning the history and culture of surfing and shaping is huge and very eye opening. The more time you spend around board building the better grasp you get of how boards work, and it not only makes you a better surfer, but also makes you a more versed individual who is in tune to what’s going on in the line up.

6. Shape of finished board? Longboard. This one in particular was made to be thinner than most with slightly turned down rails and a round outline. I wanted a log that was wide and stable but still loose and fast enough not to be too clunky.

7. Size of finished board: Length 9’6” Nose 17" Width 23 ½” Tail 16 ½” Thickness 2 ¾”

8. What blank did you use? 9’8 Y because it has more continual rocker from the nose to the tail and offered enough extra space to move the template around and play with different ideas

9. How was your board building experience? My experience was great. Being as I shaped in the box I had relatively little clean up because of the vacuum attachment which collects all of the planer dust. This also kept me from getting buckets of foam dust in my eyes which can be entirely too frustrating. Between the facilities and the advice of the guys working there I felt like I went into it with more confidence than if I’d just picked up a blank and started hacking away.

10. Did you use videos, books, web, other? I watched the JC video on shaping (shaping 101) and also picked up the surfboard construction and design book. I found both very helpful. Not to mention there is a lot of footage on youtube.com and posts on swaylocks.com which help answer any left over questions

11. What videos, books, web, other did you use? Refer to question 10…guess I jumped the gun.

12. Do you recommend these resources? I definitely recommend some form of instruction, be it through books, videos, or endlessly browsing the web. There are so many little things that a person wouldn’t even think to do, or would never know without some form of prior research.

13. What do you wish you knew going into this project? I wish someone would have told me to take my time while I was glassing and finish sanding. I’m a very impatient person and wanted nothing more than to get the board in the water…needless to say, it isn’t as pretty as it would have been had I taken the time to grind my laps and work my way up to 600grit instead of finishing out at 120g and calling it good enough. But I guess I can always go back and sand it later if I feel like it.

14. What would you recommend to someone else for their first time? Take your time. You don’t have to finish in a few hours like the pros do. The more time you take the more likely you will be to finish out with something you’ll be proud to take down to the beach and show off.

15. What tools did you find most useful? There’s so many, now that I’ve tried them all I don’t know if I could live without them. First and foremost I LOVE the EZ Square which helped keep my outline straight and even, without it I’m convinced my board would look like a crinkly fry from Del taco. The planer is awesome; being able to take the skin off the blank in a few passes as opposed to a few hours makes worlds of difference. And finally the shaping blocks with the foam pads that attach with Velcro. They work better than a normal piece of wood by giving you a forgiving padded sanding surface that isn’t too soft or too hard.

16. Where did you run into trouble? I hit a bump with my sanding block. I was using a normal piece of 2” X 6” wood, or a piece of upholstery foam. The issue was that my sanding blocks were either too hard or too soft. I came to a point while finish shaping where I was just working against myself by making more deep scratches or uneven spots. That’s why I went in and bought one of the shaping blocks that they sell in the showroom. I got the one with the medium (yellow) pad and found that all the extra scratches and uneven spots I was getting from my other blocks were taken out immediately just by having the right type of backing to my sand paper/screen.

17. What kind of fin system did you use? I went traditional and glassed on my fin. But that was only because I didn’t own a router and buying fin-rope and an extra yard of glass seemed like it would be cheaper than buying an install kit. Though I must say, that will definitely be my next investment. The ability to change and try different fins is huge, and if I want to sell the board I’m sure any potential buyer will appreciate the ability to make the board perform to his or her liking as opposed to being stuck with the fin that I liked best.

18. Did you glass the board and what was that experience like? MESSY. STINKY. And FUN. Glassing is something that every surfer should do at least once so that they can appreciate all of the great glass jobs that can be found on any surf shop sales rack. Besides, it’s part of board building, and if you short cut yourself by skipping a step in the process just because of a little mess then you’ll never fully understand the boards you’re riding.

19. What supplies were purchased from Foam E-Z? I ended up buying more than I’d planned on. The things that I didn’t buy I used in the kit that I rented (and I will end up buying all of those tools too). I had such a great time shaping that I will definitely do it again, and I’m sure that means picking up every tool to make my future creations as dialed in as possible.