- 1). Lay the four expanded polystyrene foam blocks flat on the floor in a line. This will give you the overall size of the paddle board, which will be twelve feet in length, three feet in width, and five inches in height. Glue the blocks together in this arrangement using the spray glue.
- 2). Measure 18 inches from the sides of the foam board along its length to determine where the center line is and then draw a line with a marker along the board's length as a guide to show you where the center is.
- 3). Decide what length you want the paddle board to be. A 12-foot board is a particularly long board and may prove difficult to transport. More common are 10-foot boards. Measure and cut the length of the board to your desired length using the drywall saw.
- 4). Draw guide lines that show the curve of the nose of the board and the curve at the back of the board. For the front, position a trash can lid with one point of the round lid on the front center point of the board and then align the lid with the side of the board. This will give you a very basic curve. Simply match the same line on the opposite side of the board's center point, and the outline will be done. To do the back of the board, select a small cooking pan lid to use as a template in the same way.
- 5). Cut out the curvature of the leading and trailing edges of the board using the drywall saw.
- 6). Sand the sharp corners of the board to produce the necessary rounded sides and trailing edge. When you have the sides rounded, use the sandpaper again to form the taper in the leading edge of the board. To do this, begin sanding at the mid-point of the board and sand toward the front. The thickness of the board at the front edge should be approximately three inches. The middle of the board will remain five inches.
- 7). Turn the board over so that it is facing bottom-up. Use a scrap piece of expanded polystyrene to produce a fin that looks like a shark's fin. The fin should be at least six inches long and six inches high. It should be two inches wide at its widest point.
- 8). Trace the center line around the back of the board and to the bottom of the board, and then glue the fin directly above the center line.
- 9). Perform any final shaping touches you wish to the board. Mix the fiberglass resin with its hardener and apply it to the base of the board.
Press sheets of fiberglass mat into the fiberglass resin using a wooden roller. The resin will seep into the fiberglass mat and will squeeze out of the sides. Each piece that you apply to the board should overlap the last by no less than one inch. Continue in this fashion until the board and the fin are completely covered top and bottom by one layer of fiberglass matting. When this is complete, mix another batch of resin, apply it to the board, and add a second layer of fiberglass. Continue in this way until there are at least four but no more than six layers of fiberglass matting completely covering the board and the fin. Allow the fiberglass to cure for at least two hours.
Apply the 80-grit sandpaper to the palm sander and then smooth out all the rough edges of the board until you have a uniformly flat surface. Progress to a finer grit, such as 120-grit and sand the board down some more. After 120-grit, use 220-grit and finally 400-grit. When you get to the 400-grit sandpaper, however, do not sand the upper portion of the board, just the sides, bottom and approximately one inch of the top edge. The rougher surface will serve as an anti-slip coating on the board.
Paint the board with your choice of marine paint colors using a paint sprayer. If you choose to use the kind of spray paint you find at automotive supply stores, the paint will dry to the touch in approximately thirty minutes, and you can begin sanding and buffing the finish after two hours.
Lightly sand the painted surface of the paddle board with water and the 1,000-grit sandpaper. Once the finish is uniformly smooth, apply a dab of polishing compound to the board and buff it, using an orbital buffer until the paint shows a bright, clear reflection.
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