How Much Does It Cost to Build a Surfboard in 2024?

Building your own surfboard can be a rewarding and cost-effective way to get the perfect board tailored to your needs. Understanding the costs involved is crucial for budgeting your project. In this post, we'll break down the costs associated with building a surfboard, comparing PU/PE (Polyurethane/Polyester) and EPS/Epoxy builds for different board lengths: shortboard, mid length, and longboard. Additionally, we'll discuss the minimum tools needed for the job and highlight some "nice to have" tools that can make the process easier and more efficient.

Materials Costs by Surfboard Length

The primary materials for building a surfboard include foam, fiberglass, resin, fin boxes, and a leash plug. Here’s a breakdown of the costs for both PU/PE and EPS/Epoxy builds across different surfboard lengths.

EPS / Epoxy Surfboard Build Cost

Note: Shipping costs for EPS Blanks are reasonable. We have special rates with UPS Ground to ship Engineered EPS Foam Blanks and Surfboard Building Kits for about $40 to $90 depending on your location. Costs are calculated on the webstore checkout. Shipping costs increase for lengths over 6’5” up to 7’6”. Over 7’6” must ship on a freight truck.

Polyurethane / Polyester Surfboard Build Cost

Note: Shipping PU Blanks is expensive. They are considered “oversize” because of their molded shape and most PU blanks must ship on an freight truck. Contact us for a custom freight quote for PU foam blanks.

Tools Needed

Building a surfboard requires specific tools to shape, laminate, and finish the board. Here’s a list of the minimum tools you’ll need and some additional tools that can make the process easier.

Minimum Tools

• Shaping Stand - Essential for holding the blank while you shape it.

   DIY stand build = ~$40 (wood, screws, foam rack padding)

   Shaping Stand Kit = $145 (just screw it together and start shaping)

• Shaping Tools:  

  *You don’t need a planer… more trouble than it’s worth for a beginner shaper. We recommend just using hand tools in the beginning for much better control and results.

Here is a list of the minimum amount of tools needed to hand shape a nice surfboard successfully

G-rasp: $58

Handsaw: $10

Trim Plane (if shaping wood stringer): $20

Foam Sanding Pad:$8

Sandpaper: $4

Sanding Screen: $5

DIY wood sanding block (any piece of rectangular wood) = free

Total basic shaping tools: $105

You might want to consider stepping up to the “essential” hand shaping tool kit for more helpful tools at less cost: $300

• Fiberglassing Tools:

Brushes and Squeegees for applying resin. = $10

Masking Tape: $8

Mixing Bucket: $2

Total Minimum Glassing Tool Cost: ~$20

• Fin Installation Tools cost

Cheapest: 1 ⅛” diameter hole saw and drill for FACTORY X-2 plugs = $30+

FCS2 or Futures Fin box install kit with router: ~$180 - $200

It’s a good idea to wear a respirator if using Polyester resin, and a dust mask when shaping or sanding anything. Cost ~$50

• Nice to Have Tools:

Spokeshave : fine tuning wood stringer $8

Rail Runner: Square up your outline cut and shape bottom of rail $93

Rasputin: 24” long rasp to flatten bottom and deck, remove planer marks, and foil the board $68

G-square measurement tool: Measures all dimensions of the board and fin layouts $40

Sander / Polisher: Electric sanders and polishers make the finishing process much quicker and smoother.

 $40 (random orbital) - $125 + (8” variable speed grinder)

Sanding Pads for power sanding: $10 -$42

Power Planer: Speeds up the shaping process $75- $300

Vacuum System: Helps to keep your workspace clean by removing dust and debris. A broom works very well too… Estimated Price: $125

Digital Scale: For accurately measuring resin and additives.

Why Invest in Nice to Have Tools?

Investing in higher-quality tools or additional tools can significantly improve your surfboard-building experience and the final product’s quality. Here are a few reasons why these investments are worthwhile:

1. Precision and Efficiency: Tools like a power planer and electric sanders can greatly enhance your efficiency, but hold off on these until you have built a couple boards by hand. You’ll thank us for that advice
2. Health and Safety: A good vacuum system and a respirator ensure a cleaner and safer working environment, reducing the risk of respiratory issues from dust and fumes.
3. Professional Finish: Sanders and polishers help achieve a professional-quality finish, making your board look better (not that it does anything for performance or level of fun)
4. Consistency: A digital scale ensures consistent resin mixes, which is crucial for the strength and durability of your board.

Conclusion

Building a surfboard is a fulfilling endeavor that allows you to customize your ride to your exact preferences. Understanding the costs involved in materials and tools helps you plan your project and avoid surprises. Whether you choose a traditional PU/PE build or opt for the lighter and more durable EPS/Epoxy option, the investment in quality tools and materials will pay off in the performance and longevity of your custom surfboard.

Happy shaping, and we look forward to seeing you out in the lineup with your handcrafted board!