My first surfboard build 5’10” x 20.9″ x 2.4″.
The cardboard core was more appealing than the standards EPS (Expanded Polystyrene) and PU (Polyurethane) because it comes from wood, unlike its counterparts which are petroleum-based products.
The blueprint of the core structure comes from Mike Sheldrake: https://sheldrake.net/surfboards/.
I laser cut it in a fablab, assembled it, then laminated it with epoxy resin and fiberglass.
Thinking back, I would have done my first surfboard with a normal construction. It would have been easier to learn about composite and shaping and maybe last longer.
The resulting board was quite heavy, around 4.5 KG because of the extra fiberglass layers needed. I surfed it for a bit more than 1 year. I had leaks at the beginning, I had to fix it, then I did another gloss-coat hoping it would get rid of all the remaining pinholes. It eventually did work. But I ended up breaking it with an impact against my bones which made a tiny crack prone to water leakage. I never fixed it again. It’s a decoration piece now.
cxlso – Cardboard Surfboard V1 – 2017