Shaping DIY: The Surfboard Glassing process Part 3

Intro part three: The Surfboard Glassing process

Let’s dive into part three of our extensive tutorial on DIY surfboard shaping.

In our previous episodes, we covered Part 1 Intro and Tools you need to shape your own Surfboard and Part 2 the process of shaping the surfboard yourself. Now, it’s time to move on to the next crucial step: Part 3 the glassing process.

Our focus will be on enhancing both the tightness and stability of the surfboard’s outer skin. To achieve this, we’ll be working with multiple layers of fiberglass mats and resin, effectively sealing the shaped blank. Typically, the bottom is laminated once, while the deck receives two layers of lamination.

The number of layers you choose will ultimately depend on your personal preference, taking into consideration factors such as the board’s shape, desired weight, and stability.

Should you have any inquiries on this matter, feel free to reach out to us or to Thierry André from Terry Surfboards at the Shaper House in Biarritz. But without further ado, let’s commence our glassing process.

‍Glassing is the process of adding layers of fiberglass cloth and resin to the shaped surfboard blank in order to provide strength and make it waterproof.

Here are the steps involved in the glassing process:

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Preparation:

Clean the working area from dust and dirt generated during shaping, or use a separate glassing room.
Ensure good ventilation in the room or use an exhaust system to filter out fumes.
Wear appropriate protective gear, including a respirator mask with the correct filter, safety glasses, and gloves.
Use a glassing stand to hold the surfboard blank during the process.

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Glassing the Bottom:

Place the shaped blank bottom-up on the glassing stand.
Remove any dust or debris from the surface using a hand broom or compressed air.
Roll out a layer of fiberglass cloth over the bottom of the blank.
Use sharp scissors to trim the excess fiberglass cloth, leaving at least 3-4 cm hanging over the edges to wrap around the rails, nose, and tail.
Make a cut at the nose and tail towards the stringer, known as a “release cut,” to prevent the fiberglass from wrinkling in those areas during glassing.
If desired, place printed logos or artwork under the fiberglass cloth using rice paper.

A person lays fiberglass on a surfboard in the glassing room

A closeup of a person hand cutting the fiberglass cloth with scissors

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A closeup of a person hand cutting the fiberglass cloth with scissors at the tail of a surfboard

Put on your respirator mask.
Mix the resin and hardener according to the manufacturer’s instructions.
Start glassing by pouring a portion of the resin along the stringer.
Use a squeegee to evenly spread the resin in thin, long strokes.

Closeup of hands mixing resin in a small bucket

The resin is poured onto the surfboard wrapped in fibre cloth.

The picture shows the lamination process: one person spreads the resin over the board with a squeeze.

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Distribute the remaining resin along the sides/rails and saturate the overhanging fiberglass cloth using the squeegee (the resin should flow over the hanging part and completely saturate it).
Once the resin is evenly distributed on the board, the rails need to be wrapped.
Start in the middle of the board, using the squeegee to wrap the fully saturated fiberglass cloth around the rail’s edge.
Allow the resin to cure according to the instructions provided.

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