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Alaia Wooden Surfboard project: Post 1 | Post 2 | Post 3 | Post 4 | Post 5 | Post 6 | Post 6b | Post 7 | Post 8

I’ve finished oiling the Alaia and all that’s left to do now is ride the thing. I had a lot of fun building the Alaia and meeting others out there doing the same all over the world. In the end I’m very pleased with how it turned out and I’m really anxious to go and ride it.

I applied linseed oil a total of 4 times, with a full day between applications. I was pretty generous with the linseed oil, letting it soak in for 10 minutes before wiping away the excess with clean shop rags (I used these same rags to apply the next coat). I did light sanding between coats, after the second coat I noticed it was gummy in parts where I didn’t get rid of all the excess. Sanding those gummy areas didn’t help, so I went with a Scotchbrite pad I normally use tuning snowboards and it cleaned it right up.

This is the end of this series and I open it up to any questions or comments. I’ll post an update/pictures when I get it in the water (hopefully in about 4-6 weeks). There are a few of us eager to give it a go and it should make for an entertaining session!

Posted by: Lawrence

Reading Time: 2 minutes

Alaia Wooden Surfboard project: Post 1 | Post 2 | Post 3 | Post 4 | Post 5 | Post 6 | Post 6b | Post 7 | Post 8 Finis

They say a picture is worth a thousand words. In this case I think the words better do the talking because it’s difficult to capture the progress made with the concave in a photo. I haphazardly arrived at a method for creating the concave and it goes like this…

• Snap center-line (nose to tail) with chalk
• With the belt sander on the center-line at shallow angle, I quickly and carefully sand in one direction
• With hand sander, I work from and apply pressure to the center and work outwards
• I sand a length of about 18″ at a time, using 12 strokes near the center, 6 a little further out and 3 near the edge

… I repeat this process over and over, each time making the concave deeper and feathering out toward the edges a little more. Reestablishing the center line helps keep the deepest point consistent. I happened to have a weighted metal rod I used to use when tuning skis. I place this rod on the top of the concave on one side let it roll up the other side of the concave and eventually settle in the center of the board (if it doesn’t I sand more). I included a picture of the rod as well a some calipers I’ll use when shaping the rails.

The hand sanding helps refines the work done with the belt sander. I felt a little out of control with the belt sander, but found the results more predictable when working quickly (not letting it bite too much in one place). I tried using the palm sander and it did a nice job, but the dust got out of control. It if wasn’t winter I’d be working on this project in the garage, but I’m in my workshop – which is also the boiler room , where I need to keep dust to a minimum.

The process is taking longer than anticipated, but I’m happy with the results so far. Punxsutawney Phil says 6 more weeks of winter anyway, so I’ve got nothing but time. I’ll keep working on the concave using the methods described above and start the next post on the Alaia project with the overall sanding and Linseed oiling.

Posted by: Lawrence

Reading Time: 3 minutes

Alaia Wooden Surfboard project: Post 1 | Post 2 | Post 3 | Post 4 | Post 5 | Post 6 | Post 6b | Post 7 | Post 8 Finis

Significant progress this weekend with the Alaia project. I cut the board to shape with a jigsaw, working in one direction. I said in the previous post that I wouldn’t cut the Stuth tail, but I had a change of heart. I like the side-cut it creates and given my 24 years of snowboarding I’m drawn to that shape (yeah, I’m that old and have boarded that long!).

Because the board needed to be clamped and un-clamped (3 times) I made cuts on either side of the board, with 90° cuts to remove material as I progressed. After the jigsaw work was done I used my belt sander to fine-tune the edges to get a uniform ~3mm distance from Jon’s marks (as explained in post 2).

Once I was satisfied with the shape, I used a pocket plane to put a 1/4″ bevel on the top edge (you can apply very light pressure since the Paulownia wood is so soft). Holding the plane at 45° and moving in one direction, I cut until Jon’s marks were no longer visible. After inspecting and small tweaks I flipped the board and transferred the center line which I’ll use to create the concave. I also transferred 3 perpendicular markings from the top of the board at 12″, 40.5″ and 70″ from the nose. I believe these marks were used to create the shape, but it can’t hurt to have them on the bottom.

Next I’ll work on the hardest part, the concave. Jon told me the concave should start about a third of the way down the board and Tom gave me some advice on how wide.

The board currently measures 7′ x 17 1/2″ x 3/4″. After the concave I’ll start sanding the entire board from coarse to fine grit, getting it as smooth as possible. After that I’ll oil (linseed) over the course of several days. I’ll apply 3-4 times and before each application I’ll do some light sanding to make it as slick as possible! These are the tools I used for this phase (a special thank you to Circus Boy, for without it, none of this would have been possible).

As always, check back for pictures and updates. Please also post your comments and advice. I’d really like to know if anyone else has worked on shaping their own wooden boards or intends to try.

Posted by: Lawrence

Reading Time: 3 minutes

Alaia Wooden Surfboard project: Post 1 | Post 2 | Post 3 | Post 4 | Post 5 | Post 6 | Post 6b | Post 7 | Post 8 Finis

In an attempt to experience a spiritual awakening like an ancient Hawaii commoner, I decided to try and build and surf a wooden Alaia surfboard (OK, well at least build one). Traditionally a 10-12 foot fin-less board that in ancient times were made from Ula and Koa trees, my Alaia will be about 7 feet and is shaped from a blank made from light and sustainable Paulownia wood that doesn’t absorb salt water.

I purchased two ‘Finley’ blanks (one for a friend) from Jon Wegner at Wegener Surfboards in California. Jon and his brother Tom, Surfing Magazine’s 2009 Shaper of the Year are selling the blanks here in America, but they are made in Australia where Tom lives. Purchasing the boards from the Wegner’s was a pleasure and if this project inspires you, I highly recommend you contact Jon for your blank.

Before the blanks arrived by UPS ground, I prepared my workshop with padded saw horses, jigsaw, belt sander, palm sander, hand planes, and sandpaper in assorted grits. I’m not sure I have every tool I need or is recommended, but I’ll cautiously remove material, especially the concave, which I’ll likely do in stages after sessions (assuming I have a feel for the board). Classic case of ‘you can always take off but you can’t put back on.’

When I unpacked the Alaia’s I was pleased to see the blanks arrived in perfect shape. I’m eager to begin the project, which entails cutting the blank to shape, shaping the rails and concave and finishing the board. There are a number of resources available on the web I’ll refer to, including Olosurfer.com and woodworking forums such as woodworkforums.com.

When completed, the Finley should have, according to Wegener Surfboard’s model description, “a light roll on the deck and a concave running from the nose all the way to the tail. The concave is 3/8” deep.” (Note: Jon recommended I keep more material on the board and stay within 1/4″) “This really helps keep the board from sliding sideways too much and gives the board more traction in the face.

The goal of the board is to give it just the right amount of flex. With good flex, catching the wave is easier and the board more responsive to turning.” Tom was kind enough to share the photo on the above-left of Dave ‘Rasta’ Rastovich’s board. This board has far more concave than I’ll need, but it gives an exaggerated idea of the curves.

Over the next several weeks, time permitting, I’ll be working on the Alaia and posting my experience and sharing photos on Bitness. If anyone has built an Alaia or is an experienced woodworker and can offer sage advice, I welcome your comments here, both for my benefit and anyone else interested in the Alaia.

Posted by: Lawrence