Materials List
Here is a materials list for building a hollow wood paddleboard. I usually buy 5 rough sawn 2" x 6" boards that are at least 4" longer than the boards length. This yields more wood than you need but ascetically it is nice to have some wiggle room. If you buy boards that are more than a foot longer than you need you can cut off excess as your solid blocking before you mill it into 1/4" strips and planks.
Wood
Quantity
Item
Information
1
Internal Fishbone Frame
Start with a CNC Fishbone or build your own fishbone out of 1/4" plywood and a set of plans. (full-sized templates)
1
Rocker Table
The rocker table is a series of risers that sets the boards rocker and bottom contours. A PDF set of templates are currently included with purchases or there is a tutorial showing you how to construct your own in the tutorials section of the website.
2
1/4" Planks or Strips
These planks or strips will become the top & bottom panels and should add up to the 1" wider than the boards width and be 6" longer than the a finished board.
4
1/4" x 3/8" Outline Strips
2 - Outline strips - plus 2 strips to reinforce the standing area.
2
1/4" x 3/8" Foundation strips
2 strips with only a bead edge used to start the rails.
30
1/4" x 3/8" Rail strips
Strips with both 1/4" sides milled with a bead and a cove.
1
Nose Blocking
A small cutoff of 2" x 4" or 2" x 6" lumber.
1
Tail Blocking
A small cutoff of 2" x 4" or 2" x 6" lumber.
1
Fin Blocking
Minimum size for wood: 3/4" x 1 1/4" x 12" EPS Foam: Add 1"
1
Handle Blocking
Minimum size for wood: 1" x 2" x 8" EPS Foam: Add 1"
1
Leash Blocking
Minimum size for wood: 1 1/8" x 1 1/8" x 1" EPS Foam: Add 1"
1
Vent Blocking
Size depends on method of blocking.
4
FCS Blocking (Optional)
1 1/2" x 1 1/2" x 1 3/4" for wood. EPS Foam is not recommend.
Inserts
Quantity
Item
Information
1
Handle
The plastic inserts listed can be purchased from Fiberglass Supply in Burlington WA or from Swell Composites in Richmond BC.
1
10 1/2" Fin Box
Fins unlimited box is the most common.
1
Vent
You can purchase plastic screw vents like I use in the tutorials or make your own from a brass bolt and rubber O-ring.
1
Leash Plug
1" Leash plug with brass post.
4
FCS Plugs
If you are installing thrusters (side fins) you need 4 FCS plugs or 2 Futures style inserts. You do not require thrusters for flat water paddling.
Glass & Glue
Quantity
Item
Information
24'
37" x 4oz E-Glass
1 layer of 37" wide (1522) cloth on the top and the bottom. If you can't find 37" wide cloth just buy the next wider size as you will not be able to wrap the rails with 30" cloth.
1.5 gallon
Epoxy
You will not use the full 1.5 gallons (1 gallon of part A and 1/2 gallon of Part B) of epoxy but it works out cheaper to buy the 1.5 gallon kit than to run short on the next smaller size.
1 Sheet
Acetate Film
You can make your own logo by printing on overhead projector film following this tutorial.
1 Quart
Spar Varnish
Epoxy likes UV protection to prevent it from yellowing in time.
1
Titebond 3
1 Large bottle should be enough for making all wood-to-wood connections.
1 tube
Pl Premium or 3M 5200 Fast
This adhesive is used to fix the fishbone to the bottom skin.
Shop Supplies
Quantity
Item
Information
1 roll
1.5" Painter's Tape
Green tape works well for general purpose.
1 roll
1" Blue Painter's Tape
Blue tape is best for doing the transition line from the rails to top deck as the dark colour is easier to see under the wood.
1 bottle
Denatured Alcohol
Used as a thinner for epoxy.
1
Sand paper
80, 100, 150, 220 grits of regular sand paper.
4
4" Chip Brushes
Used for the epoxy hot coat and gloss coat.
6
3" Foam Bruches
Cheap disposable foam brushes work well for applying varnish.
1 sheet
Wet/Dry Sandpaper
320, 400, 600 are used to polish the varnish.
Box
Disposable Gloves
You do not want epoxy on your skin.
