BOBSLEDS by Bob Johnson

1. Your Name: Bob Johnson

2. Your Brand name: BOBSLEDS

3. How did you hear about us? The internet (Surf line)

4. How was your initial experience at Foam E-Z? Unreal! The people there are the best folks I have ever had the pleasure of doing business with.

5. Why did you want to build your own board? Design and build better surfboards.

6. Shape of finished board? Round pin Glider

7. Size of finished board: Length 9’7" Nose 17 3/8" Width 23 1/2" Tail 16" Thickness 3 5/16"

8. What blank did you use? Custom 9’9 B US Blanks Blue with triple Cedar stringers


9. How was your board building experience? Great and made all the better with the assistance of Foam E-Z for getting me whatever I need to build boards.

10. Did you use videos, books, web, other? Not recently, but there are some good ones that Foam E-Z sells that can show you some good stuff. The Master Shaper and Glasser series are probably the best.

11. What videos, books, web, other did you use? Always reading every Surf journal and book I can get my hands on. You see a lot of cool boards for ideas that way.

12. Do you recommend these resources? Absolutely.

13. What do you wish you knew going into this project? How quickly this board would sell. It really was A LOT of work to build and having someone grab it up so quick was gratifying and a relief.

14. What would you recommend to someone else for their first time? Be patient, never rush, don’t settle for good enough, do your absolute best.

15. What tools did you find most useful? My Clark planer and Milwaukee grinder are indispensable as well as my block planes, surforms and custom made sanding pads and well worn screen. And then there are my custom grinded squeeges for laminating and hand cut brushes for other glass work, buckets and hey…really good scissors! (All available at Foam E-Z)

16. Where did you run into trouble? Cold weather glossing is never boring, but it’s all good now!

17. What kind of fin system did you use and why? Fins Unlimited 10.5 inch single fin box. It is a solid set-up and allows for many different fins to be used in different positions. Also, the neutral feel of a single fin is the perfect compliment to a glider board like this.

18. Did you glass the board and what was that experience like? Yes, and those are RESIN panel inlays in red on the deck, NOT airbrush. It was challenging and fun !



19. Where did you shape and glass your board? In my Garage/Shop.

20. What type of board do you want to make next? I have an order for a 8’3 hybrid/egg for So Cal.

21. Thanks again to the Foam E-Z crew for all the help they have provided. Thanks to my top riders and best friends David Ferreira, Austin Ferreira, Adam Ferreira, Derek Bostleman, John and Shane Greer, and the amazing Mike Andreason : Thanks to my Fiance Anna, my little girl Marisa and my Mom.

Icon Surfboards by Dave Reynolds

1. Your Name: Dave Reynolds

2. Your Brand name: Icon Surfboards

3. How did you hear about us? Sacred Craft, Ventura, Spring 2010.

4. How was your initial experience at Foam E-Z? Rad + chill

5. Why did you want to build your own board? A head full of Thoreau, a taste of ennui, and a penchant for sculpture. Simply, I knew I wanted to shape a board for a long time because I knew it would be fun.

6. Shape of finished board? Wonky Thruster

7. Size of finished board: Length = 6’1” Nose = pointy Width = 18 1/2” Tail = 6” Thickness= 2 1/8”

8. What blank did you use? Marko recycled Envirofoam

9. How was your board building experience? Fun + cool

10. Did you use videos, books, web, other? Mostly talking with professional shapers and glassers - not being afraid to look foolish or ask a dumb question. Searching Google was helpful. I used the net a bit but by the time I started to surf the net, I was ready so I just went for it. Listening to Grant at Foam E-Z and Steve at Aloha Glass was the best. I later bought the book Essential Surfing which is helpful.
11. What videos, books, web, other did you use? See answer to question #10.

12. Do you recommend these resources? Yep.
13. What do you wish you knew going into this project? That I’d move three times, break up with my girlfriend twice, and get really busy at work.
14. What would you recommend to someone else for their first time? Practice patience and have another board to surf in case the swell comes up and you want to go surf. Eat really well, educate your mind, listen to good music, and have some extra cash for when you get hooked.

15. What tools did you find most useful? My ears, just listening to the talented shapers and glassers. A rooter would be nice. I like the vibe of using all hand tools, but it’s slow, so some big ol’ power tools would be rock-n-roll.

16. Where did you run into trouble? Got a little carried away shaping, I whittled the thing into a toothpick. I used a real outline form the second time. Furthermore, I didn’t wet the laps enough on the bottom so when I pulled the rails they got a bit dry which led to bunching later on in the build. I also forgot to put the leash plug in which was pretty amateur.
17. What kind of fin system did you use and why? Futures, a stronger, more efficient system; and I like their fins.

18. Did you glass the board and what was that experience like? Yes, a bit tricky but one of my favorite parts of board building. So fun, especially the Super Sap – the maple syrup smell is kind of trippy if you’re used to the headache old school stuff.

19. Where did you shape and glass your board? Shaped at Foam E-Z in the back, like a regular home style coffee shop over there. Nice guys, good ideas, and they don’t mind if you take your time. I glassed my board at my buddy, John Summerville’s woodshop in LA. He makes world-class custom boats and furniture. He had some essential tools around to make things a bit more convenient and a good guy to kick back with as everything dries.
20. What type of board do you want to make next? I already shaped a 5’6” extra wide quad. Minimal rocker, strong V out the tail. Super fast and loose. I customized the glass on this one with a brown bottom with flicks of blue, orange, and yellow, with a white pin line. Next is a 7’6” fun board for a friend, and a DVS inspired quad fish for myself.
21. Feel free to add any other input or interesting information you’d like… ”All is, if I have grace to use it so, as ever, in my great taskmaster’s eye.” - John Milton.

DDonn Shapes

1. Your Name: Davis Donnell


2. Your Brand name: DDonn Shapes


3. How did you hear about us? Can’t remember to tell you the truth. I live really close and always drive by on my way to work.


4. How was your initial experience at Foam E-Z? Excellent. The guys behind the counter were super willing to help!


5. Why did you want to build your own board? The experience and to have a killer retro board.


6. Shape of finished board? Think of a mix between a 70’s single fin and a modern single fin…


7. Size of finished board: Length 6’2” Width 19" Thickness 2.5"


8. What blank did you use? 6’5”A US Blanks Fish


9. How was your board building experience? Went smoother than I planned. Glassing was a PITA!!


10. Did you use videos, books, web, other? All web and the guys at Foam E-Z


11. Do you recommend these resources? Yea, I recommend looking more into glassing than I did if you plan on glassing yourself!

12. What do you wish you knew going into this project? How to properly cut the fiberglass to make it even.


13. What would you recommend to someone else for their first time? Have someone else glass it!


14. What tools did you find most useful? Surform without a doubt!


15. Where did you run into trouble? Glassing


16. What kind of fin system did you use and why? 10.5 in Fin Box. I wanted the option to change fins out and have a good time with it.


17. Did you glass the board and what was that experience like? Yup. Ugly.


18. Where did you shape and glass your board? My shed. Made a mess but was worth it.


19. What type of board do you want to make next? A 10’ Log

Rubio Surfboards by Chris Gonzalez

Your Name: Christopher Gonzalez

Your Brand name: Rubio Surfboards

How did you hear about us? Online

How was your initial experience at Foam E-Z? Great fast service great experience.

Why did you want to build your own board? been surfing for many years and wanted to explore new trades.

Shape of finished board? Retro Pintail

Size of finished board: Length 5'8" Width 21 1/2" Thickness 2 3/4"

What blank did you use? US Blanks 5'10"RP

How was your board building experience? great very smooth

Did you use videos, books, web, other? web and the helpful staff of Foam E-Z

What videos, books, web, other did you use? YouTube

Do you recommend these resources? yes

What do you wish you knew going into this project? better sanding technique

What would you recommend to someone else for their first time? work on your glassing on small pieces of scrap foam

What tools did you find most useful? sanding block and planer

Where did you run into trouble? sanding
What kind of fin system did you use and why? FCS Fusion System since it was easier to install

Did you glass the board and what was that experience like? Yeah, don't wear thin pants it was hot hahahaha!

Where did you shape and glass your board? in my shop

What type of board do you want to make next? all types of boards

Bob Johnson's Custom Triple stringer Gun

1. Your Name: Bob Johnson

2. Your Brand name: Custom Surfboards by Bob Johnson

3. How did you hear about us? Surfline

4. How was your initial experience at Foam E-Z? Excellent! A great experience.

5. Why did you want to build your own board? I just always have had it in me since I was a kid.

6. Shape of finished board? Hybrid longboard gun round pin

7. Size of finished board: Length 9’1" Nose 12" Width 23" Tail 12-1/4" Thickness 3- 1/8

8. What blank did you use? 10’6 A blue custom triple stringer (bass & cedar)

9. How was your board building experience? Always epic !

10. Did you use videos, books, web, other? Just my hands and brains

11. What do you wish you knew going into this project? How fun it would be.

12. What would you recommend to someone else for their first time? Patience

13. What tools did you find most useful? Any tool that is used correctly with skill.

14. Where did you run into trouble? Where didn't I? That is board building, always solving problems and then eliminating them next time aka. Experience!

15. What kind of fin system did you use and why? Single fin box. The board was built primarily for Sunset in Hawaii and big La Jolla reef breaks, therefore it is much easier to travel with a removable fin system. Next, I love the ability to lay it on a rail and the smoothness and feel of a single fin gun in big waves.

16. Did you glass the board and what was that experience like? Yes, Fantastic !

17. Where did you shape and glass your board? Garage (shop)

18. What type of board do you want to make next? Too many to list, but a keel fin fish and a big glider are up there on the list.

Thanks to everyone at Foam E-Z for all they have done for me. I have never known a better, nicer group of guys with skills to boot ! I have actually been building boards for about 6 years now and things are coming together. Please allow me to thank the following for their help and support:

*My Mom and girlfriend
*San Clemente legend and red hot ripper Mike Andreason for his assistance with board design, R &D, feedback and other mayhem……..
*David, Austin and Adam Ferreira
*Jack Reeves
*Craig Chapman
*Bruce Jones
*Greg Martz
*The Chipper
*Sunset Beach HI
*The stick 6 crew
*The Foam E-Z crew

Ascent Surfboards (Calvin Chau) Creates a Finless Bat Tail Gem!

1. Your Name: Calvin Chau

2. Your Brand name: Ascent Surfboards

3. How did you hear about us? From the strong onshore winds after work… and Sacred Craft!

4. How was your initial experience at Foam E-Z? Very helpful without being intimidating to a weary first time shaper. Brad and Grant set me up with the right tools and more importantly, the right knowledge.

5. Why did you want to build your own board? This is my first finless shape. I wanted to understand the subtleties in board performance by applying different design elements.

6. Shape of finished board? A finless bat!

7. Size of finished board: Length 5’9” Width 20” Thickness 2 1/4”

8. What blank did you use? Marko Foam 6'1" Pescado Fish Blank

9. How was your board building experience? Channels are a new challenge, but also fun. Grant recommended using the rounded surform blade which worked very well. Placement of the channels was the toughest part but I finally decided on where they should go and just started working away. The shape was Derek Hynd inspired.

10. What videos, books, web, other did you use? JC’s Shaping & Glassing 101, Greg Leohr’s Epoxy 101, Swaylocks Forum, YouTube,

11. Do you recommend these resources? Yep, the dialogue in JC’s Shaping 101 is helpful for learning.

12. What do you wish you knew going into this project? Cutting out a U-shaped spreader to use for the channels while glassing.

13. What would you recommend to someone else for their first time? Don’t be afraid to try shaping. The initial investment may be steeper than you’d like, but the accomplishment you’ll feel afterward is WAY worth it. Don’t expect a perfect board, it’ll look something like a surfboard and it’ll be surfable. Watch JC’s Shaping 101. And wear a respirator; you don’t want this stuff in your lungs. Use slow curing resin when glassing for the first time.

14. What tools did you find most useful? Electric Planer, Rounded Surform blade, Sanding Block, Calipers made from scrap plywood

15. Where did you run into trouble? Glassing the channels.

16. What kind of fin system did you use and why? NONE! (I’ve been waiting for this question =P)

17. Did you glass the board and what was that experience like? Yep, Grant challenged me with using R&R Kwik Kick and it didn’t prove to be too tough. Hardest part is blue tinting on EPS with 4 deep channels. The bat tail another difficulty to add on top of it all.

18. Where did you shape and glass your board? In my garage via a homemade shaping stand.

19. What type of board do you want to make next? A twin fish? A quad? A longboard? We’ll see.

Matt's Wisconsin Masterpiece!

Hey Foamez,

I just built my first board and got it out on the water a couple of times. I was hoping to get some advice / constructive criticism.

That being said...this was my first board I've ever made (all hand tools, from FOAM-EZ, represent). I realize it's far from perfect and has many mistakes (which are visible). I took the approach that more foam is better than less when it came time to hack off more to fix mistakes.

My nose and tail are to thick and the outline has a few small kinks. I tried to keep my rails pretty standard, round 50/50 and was fairly successful. My goal was to make a great lake board that was thick and wide as possible. It's about 2 3/4" thick in the center and about 22" wide. I kept the rocker pretty standard to how it came, so I don't think there is a lot of issue there.

It drops in real nice and grabs real small waves..but once underway it loses power and is hard to keep going. It turns great though. A lot of it I'm guessing is from small closed out waves we get most of the time.

Being in Wisconsin, I didn't exactly have a lot of resources to use, so I did a lot of things on a trial and error system, if you know what I mean.

My real question is: the overall outline/proportion of the board. I wonder if there is to much board in the bottom 2/3 area or more board should have been pulled towards the top? Or maybe not, I was wondering if I could get your advice on the overall shape and proportion of the board.

I appreciate you taking the time very much. I attached some pics of it and in the water to try and get a better idea.

Can't wait to start on my next board. Any idea when you'll get some marko 9'6" blanks in?

Thanks again for everything,

Matt

First off, congrats on building your first board all the way through, that in itself is a huge accomplishment that you should be proud of!! It's always difficult to give constructive criticism through pics/email but I'll try. Regarding your outline, you gotta remember that it all starts with the plan shape. If you start with a nice flowing outline without kinks and bumps then you set the tone for the rest of the shape job and vic-a-versa. In surfboard design there is no right or wrong because it is up to the shaper to design a board for specific conditions, the surfers experience, and weight/size. So if it looks like there is a bit too much volume in one area of the board then you're probably on to something. The thing to remember is that you learn from each board, try not to make the same error twice, and to have fun with it. I think you're on the right track. Thanks for sharing this with us and let us know if we can help you out in the future.

Grant