- 1). Draw out the longboard shape on a large piece of paper. If you have a longboard deck available, you may wish to use this to help you create the outline. Be creative, as your deck can feature a length of anywhere between 35 inches and 60 inches. This outline does not have to completely mimic a surfboard's appearance, but it should fall close. Cut this longboard outline out from the paper.
- 2). Lay a piece of the plywood down on a flat surface before you. Spread urethane glue evenly across the surface of this deck, making sure to eradicate any bubbles or excess glue from any areas.
- 3). Place a secondary piece of aircraft plywood on a flat surface before you. Dampen a sponge and wet the entire surface of this plywood. Stick the wet side of the plywood on top of the first piece with the urethane glue.
- 4). Drill screws into the perimeter of this plywood amalgamation, holding these two sheets together securely while the urethane glue dries. Let the glue dry overnight, then remove each of the screws to resume work.
- 5). Cut any excess glue that seeped through the ends and edges of the plywood with a craft knife. Throw any of this glue away to clear your work space.
- 6). Place the paper outline on top of your glued sheets of plywood. Carefully trace this outline with a pencil so that you have the basic shape of your deck drawn onto the wooden surface. Clean up any lines once you are finished, ensuring that this outline represents the exact dimensions of your longboard.
- 7). Cut the outline of this skate deck outline from the plywood sheets with a circular saw. Attach the 120-grit sand paper to the belt sander and polish the sides of this skate deck outline, ensuring that the edges are rounded and smooth.
- 8). Drape the fiberglass cloth over the bottom of your longboard deck. Cut this cloth sheet so that only about 1 inch of room around the edges of the outline.
- 9). Mix the epoxy resin with the hardener to create a strong, adhesive material suitable for your fiberglass cloth. Apply this mixture evenly to the bottom side of your skate deck and position the fiberglass cloth sheet appropriately. Squeeze out any bubbles or creases that may have formed during this process, then let this deck dry.
Cut the excess fiberglass cloth from your skate deck. Use a belt sander on the bottom and top surface of your fiberglass longboard, ensuring a smooth texture. Lay a piece of griptape to the top of your board, then cut the sides with the craft knife.
Place large riser pads on each end of the longboard, making sure these two pads are evenly spaced. Use the 7/8-inch bit and drill through the holes of the riser pads, creating sections for each of the longboard trucks to attach. Your trucks should be about the same width as your longboard at its widest point. If your deck is 8 inches wide, use 8-inch wide trucks.
Set a truck on top of each riser pad, then secure with the nuts and bolts that came with your skateboard hardware. The riser pads allow larger wheels — especially 58 millimeter to 72 millimeter wheels — to spin without rubbing against the deck during turns.
Place a bearing on the end of one of these trucks, then slide the wheel over this section. Press down on the bearing with the wheel until it snaps into place, then flip the wheel to secure the second bearing. Repeat this process for the remaining three wheels.
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