Back in November of 2014 I took a roadtrip to Norcal, and on my way South, in Salinas, I picked up a 10' Western Red Cedar 2x4, which was to comprise 4 of the 6 hull planks on what is going to be my Final hollow Cedar surfboard. The rest of the board is made from leftover Cedar planks from the other boards I built, the last one being built 12+ years ago.
It was not the lightest piece of wood I could have selected, but its beauty and character was undeniable with nearly all shades of brown, along with tan blonde with a few purple and pink hues thrown in too.
I did not take it to my table Saw until nearly September of 2015, and have been slowly building the board ever since.
I decided upon a 6'11" x 22" x 3" double wing round pin with 5 proboxes. I have had 6 other boards of this same general outline which I always called my shortboard, but which others might classify as a hybrid or a speed egg or Ugg, a 'funboard'.
My first of this general style surfboard was back in '96 and I knew then and there, I was pretty much done with pointy nose shortboards for good, back in my 20's. Now at 46, 43 at the start of the build, I wanted something to last me for the rest of my life that could paddle well, go fast, and turn hard. I weigh 210 to 220 Lbs with about 20 of that being a spare tire round the middle. Been stand up surfing since 12, and prone wave riding since 8.
Not having built a HWS in 12 years, I had 12 years to develop my wood working and problem solving skills to address the weaknesses I found in the structures of previous HWS boards. I went a bit overboard, and decided to not rush any single stage. Previous builds were done in as little as 2.5 weeks. This one is at 2+ years. I took 2.5 months shaping it, but all throughout this build there was a period of weeks in a row, where I did not even touch it.
While I am not comfortable showing the complete internal structure of this board, it is not built in the same style as most HWS are. I use 5 stringers, cut my rails out of a 1x12, taper and stack them onto the outline, building the rails square for later shaping. The pieces which go from stringer to stringer are more numerous than most builds I have seen, but I am always imaging a well placed knee in the center of a 'chamber', and then there magically appears to be a support installed there despite the added weight.
Nearly every internal peice is fiberglassed. the center stringer is two layers of cedar with 8oz fiberglass in the middle and 1.43oz on the sides, all other of the 4 stringers are glassed both sides with 1.43 oz.
The interior of the hull is glassed with 1.43oz, the interior of the hull is glassed with 1 layer, perhaps 2( can;t remember) of 1.43 oz and 1 layer of 3.7oz e cloth.
I was aiming for it to come in under 12 pounds but that became a pipe dream about 8 months ago, and expect it to finish up in the mid 14lb range, hopefully less. It is not getting a thick exterior glass job with just one 1.43 layer on the hull one on the deck with a few stomp patches, and minimal rail lap.
Which is fine, my 6'8" x 20.5" x 2 5/8" HWS now weighs 15.5 lbs having had multiple repairs, so this one will have significantly more volume and will weigh less. I have a moderately glassed foam PUPE version of the 6'8" which comes in at 10.5 lbs and I prefer the 15.5lb HWS as long as it is chesthigh+. Anything less than this and I am usually on a traditional sytle longboard anyway
I always liked heavier boards, and there is something strange about HWS, in that they do not feel as heavy underfoot as expected. Definitely not for HPSB'ers or those with a disposable mindset, but all i care about is my wave count and going fast and turning hard and pulling in when possible, and I feel the HWS is not a limiting factor for doing this.
All other HWS I built had very mild bottom contours. Either flat to a V, or a subtle triple concave. I had tried a 7'x22'x3" board with a fairly deep double to single to double a few months prior to beginning the build, and liked how engaging it felt, and decided to incorporate deeper concaves into this build.
These concaves required being built into the close tolerance blank, as the planks start out just over 3/16" thick and I try to not let them get under 1/8" thick when shaping. This desire for deeper concaves built into the close tolerance blank basically required a complete different build method than every other HWS I have built, and much of what i had learned on previous builds would be inapplicable to this build, and the new build might have design flaws in the structure that would not become apparent until failure. Much time was spent thinking how best to distribute the strength across inherent weak spots, or make the super strong parts weaker. Not sure I had the foresight to negate them all but time will tell.
I get 5 planks from a 2x4, 4 of which are bookmatches and the fifth, was put aside for making fins.
To get the 22 inch width, I needed to add ~1.5 inches to the cedar planks., I had some nice dougfir already milled to the proper thickness for some other task, and while I knew it would add weight compared to using more WRC, I always liked racing stripes.
I just glassed the deck on theis board last night, Will soon be installing the proboxes, and hope to have it ready in the next week, but this timeframe, like much of the expectations on progress on this build,could be a pipe dream.
I will add more to this thread while I finish up the board.
Please keep in mind i am well aware there is little to no love for HWS on this forum. The board is already built, shaped, and glassed. I am not looking to improve the design or build method, or teach anyone else exactly how I did it.
I built this board for me, not for anybody else, and it is not for profit, or recognition. If you see me carrying the board, please ignore me, as I do not like the attention of strangers. Thankfully, with the proliferation of the pop out asian veneered boards, a wood surfboard does not garner the attention it did a decade + ago, but pawlonia veneers do not much look like WRCedar either.
I am fully relcutant to even start this thread, but I told Huck i would 2+ years ago, and seeing his new thread about a 'hunk of wood' and his relatively quick progress on it, and my recently having glassed my own project, seeing the character of the cedar revealed when saturated with epoxy, felt I should get over it.