Build a Board

Once you have your CAD generated , here is how to make your deck!

Materials:

Epoxy - I prefer the totalboat crystal clear epoxy but most 2 part resins should work. West Systems is another popular (albeit more expensive) choice
6 oz Fiberglass cloth pretty much any 6 oz biaxial weave cloth will work and you will need about 3 yards of it.
Wood glue - I prefer tightbond
MDF - 2’x4’ sheet ¼” thick
Skateboard trucks - Penny Nickel trucks work great - but any 4in truck should work
Bearings - I use Bones Reds. They are great bearing and super cheap
Hardware - any 1.25" skate hardware
Wheels - Any 60mm or less wheel will work. I prefer Orangatang Stimulus or Shark California Rolls
Plastic sheeting - to keep you deck from being glued to things that you don't want it to

Tools:

Latex Gloves
Sandpaper - some 120 and 220 grit
Clamps - Big C-Clamps work best but any wood clamp should do.
Respirator - epoxy and fiberglass can be nasty - protect your lungs
Bandsaw
Blocks to prop up the deck - lots of things will work here chunks of 2x4 old coffee cans, etc.
Well ventilated work area
Cheap brushes - I prefer foam brushes as you don’t risk losing bristles in the epoxy. Harbor freight has a super cheap set
Razor blade - I find snap knifes to be the most effective
Laser cutter - if you do not already have access to one most make spaces have them

Step 1:

Cut out two of the board outline generated by HexDecks , and five of the tail.dxf out of the ¼” MDF on a laser cutter

Step 2:

Align the pieces, put glues on each side and then clamp together. Let the board sit until dry.

Step 3:

Take the board and cut the stacked tail to shape. Then sand until you get your desired shape. Make sure to round over all of the sharp edges on the board as the fiberglass will not lay nicely on sharp corners.

Step 4:

Prop your deck core up on some blocks. Make sure there is a layer of plastic between the core and the blocks so that the blocks do not become adhered to the deck.

Step 5:

Cut a 18 inch wide piece of fiberglass and drape it over the deck. Take your time here, the better the fiberglass drapes the better your end product will be.

Step 6:

Mix the epoxy and carefully saturate the fiberglass. Be careful to apply too much as the excess with fill in the holes in the MDF and make your deck heavier than it needs to be. Start the next layer immediately after the first has been applied.

Step 7:

Repeat with additional layers until you have the required number and then let dry four a couple hours.

Step 8:

Before the epoxy has fully cured but has set enough that it can be handled, cut the excess cloth off of the deck. If you wait for it to dry completely this becomes quite difficult. Then let fully cure.

Step 9:

After it is fully cured, sand the backside smooth, and clean out the hole. Any debris in there will be stuck forever if you don’t remove it now.

Step 10:

Repeat steps 6-9 for the other side of the board.

Step 11:

After the board has been fiberglassed on both sides and the edges have been cleaned, mix some more epoxy and brush a coat over each side to fix the rough surface made by the cloth.

Step 12:

Sand and finish to your liking, but be careful to not sand through the cloth layers.

Step 13:

Attach hardware and grip tape and go ride! Don’t forget to share a picture with us! We would love to see your creation!

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