HOW TO BUILD A STAND UP PADDLE BOARD

1. Do you sell paddle board templates?

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2. Going to shape a SUP. Thinking about a 9'6" blank and shaping to about 9'6". I have a Fusion install template and router bit and fin jigs. Are there FCS fusion fins and fin setups for a SUP? What do I need to cut out for the handle?

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3. Do you sell SUP blanks?

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4. I purchased two Vented Leash Plugs and want to know what the expected lifetime of the membrane is. I think you guys have the right idea putting it in the leash plug, my only concern is what happens when the material wears out?

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5. I have bought a vented leash plug V3.14 and I need to install it but I cannot access the video of installation as I cannot get on to youtube. Could you just send me some instructions of how to install it.

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6. I'm building a SUP with EPS foam and need some epoxy resin - about 3 gallons, I think. I've seen some videos showing glassing with 2 layers of cloth. Can I do that with 3 layers or should I do 2, then the third? Your thoughts?

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7. If I purchase the FCS SUP handle with Vent. will that be enough ventaliation for the boards or do I need another vent or vented leash plug as well?

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8. I have seen some people install the fin box and handles first before glassing and some install after the glassing. What to you recommend for a first timer?

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9. I want to know if the vented leash plug is necessary for EPS shortboards . I also wanted to know if a vented leash plug works ok on all size of paddle boards (SUPs for surf, recreational, touring and race boards) because of the foam volume.

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10. How should I store finished sup boards. Laying flat but no room , can't stand up because ceiling is 8 ft. So on their side on my old weight bench converted into an sup rack. Will this angled warp the shape of the board

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11. The SUP blank is already cut to the specifications on the website? So, if I really wanted to keep it as is then I could glass it out the box without any cutting or shaping?

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12. How much fiberglass do I need for my SUP?

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13. How does the carbon fiber stringer work on the SUP ( is it in the board?)

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14. How many vents does my SUP need?

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15. I was also looking at your futures SUP handle and was wondering is there a bottom structure to it or is it open. My SUP is a hollow core so an open box would create a problem for me.

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16. am interested in a SUP blank. I need it to support 240lbs. What length board would be best to do that?

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17. Which fin and fin box do you recommend for a 10’ 6” paddle board. I also need glass and epoxy resin for this board, what do you recommend?

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18. I need a SUP to support 240lbs. What length board would be best to do that?

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19. Do you have detailed instructions on making a SUP?

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20. I'm building a SUP. I've seen some videos showing glassing with 2 layers of cloth. Can I do that with 3 layers or should I do 2, then the third? Your thoughts?

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21. I bought 2 of the 11'6 SUP blanks from you guys and have now finish shaping them. I will need supplies for the step to finish the boards.

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22. Is the SUP handle installed before glassing the deck or after?

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23. Using VectorNET and 4 oz S-2 glass on my SUP Shape

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24. How many vents do I need for my SUP?

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25. Can I install vents in the board before glassing like fin boxes?

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26. Would an additional carbon fiber strip on top of the SUP (in addition to the one on the bottom) make the board stronger?

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27. Do you have a multiplier for rail bands dimensions for a SUP?

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28. Should two of your vented leash plugs be enough to handle one SUP? My SUP is delaminating.

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1. Do you sell paddle board templates?

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Yes, we do offer a universal SUP template. It can be used full length to 12'6" or you can take any length from the middle of the template to get your desired length. You can make the board wider or narrower by sliding the template further or closer to the stringer. 

The SUP template can be ordered here

Greenlight has developed a technique to allow anyone with a printer to make full scale templates for any surfboard outline imaginable. We segment the outline into 8.5" x 11" regions and add registration marks so the segments can be cut out and taped back together accurately.


Templates are emailed within 24 hours after purchase  in Adobe Acrobat PDF format and are printed on normal 8.5" x 11" paper. (No Scale)



2. Going to shape a SUP. Thinking about a 9'6" blank and shaping to about 9'6". I have a Fusion install template and router bit and fin jigs. Are there FCS fusion fins and fin setups for a SUP? What do I need to cut out for the handle?

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Our 9'6" Sup blanks sound perfect for your project and come with a pre-cut outline.  
As far as fins are concerned a lot of fin selection comes down to the weight of the rider. Any FCS twin tab fin will work depending on your weight and what dynamics you want from the board. Bigger fins will give more hold and drive while smaller fins will be loose and slide a little. Can't go wrong with the FCS M5 or G-AM sets. On the days we want more hold we typically make our surf sups quad +1 so we just pop in the center fin and two side fins.

We sell the Futures SUP handle install kit for the futures SUP handle (we recommend installing 2 vented leash plugs if using this handle). or you can freehand the route if using the FCS SUP handle with Goretex Vent (we recommend adding an additional vented leash plug for a SUP to prevent delaminations)

3. Do you sell SUP blanks?

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YES we have SUP blanks and complete kits! We have stock 9'6, 10'6, 11'6 and 12'0 SUP Blanks. They have the outline cut for you already to save a lot of shaping work. 

We also custom cut EPS SUP blanks per your design on our CNC hotwire machine up to 14' long.

4. I purchased two Vented Leash Plugs and want to know what the expected lifetime of the membrane is. I think you guys have the right idea putting it in the leash plug, my only concern is what happens when the material wears out?

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Our Vented Leash Plugs have been in surfboards and SUPs for over 7 years now worldwide with no reports of degrading over time. We recently developed a new improved membrane we call "G-vent" to replace Goretex which is the standard venting material. 

If you are concerned with longevity of the membrane then you can rinse with fresh water as the only thing that can do wrong with the membrane itself is getting clogged with salt particles from ocean water. But that is very unlikely since the microscopic membrane is smaller than water moleucules.

You can be confident in the lifetime if our vented leash plugs.

5. I have bought a vented leash plug V3.14 and I need to install it but I cannot access the video of installation as I cannot get on to youtube. Could you just send me some instructions of how to install it.

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Here is a link to the Vented Leash Plug Install Video

We can guide you through the installation of the VXV. It's simple.


Use a 1 1/8" (28mm) holesaw and drill about 5/8" (16mm) Deep.


Remove the foam and stringer material


Knead the putty in your fingers for a few seconds and roll into a rod about 1/8" (3mm) diameter


Wrap the putty tube around the base flange of the plug - this acts as a resin damn so resin does not flow under the plug and clog the vent.


Push the plug with putty flange into hole and use the small stick to tamp the putty down making sure it spreads to the edges of the hole you drilled. A little water on the stick helps it not get stuck in the putty.


Mix a small batch of resin (add cab-o-sil if you want to thicken it) and pour around the perimeter of the hole, filling it up. 


When cured sand the plug flush with the board and you're all set.

6. I'm building a SUP with EPS foam and need some epoxy resin - about 3 gallons, I think. I've seen some videos showing glassing with 2 layers of cloth. Can I do that with 3 layers or should I do 2, then the third? Your thoughts?

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Our Engineered EPS SUP Blanks require only 2 layers of glass on the deck due to the increased foam strength but you can certainly add as many layers as you'd like for additional strength. 

Laminating 2 layers at a time is the easiest way. The resin will saturate through 2 layers easily but tends to create air pockets when soaking 3 layers at once, making the glass job weaker.

So yeah, do 2 layers and you can immediately roll out the 3rd layer of glass, cut, and saturate it. It will use a bit less resin that way too.

7. If I purchase the FCS SUP handle with Vent. will that be enough ventaliation for the boards or do I need another vent or vented leash plug as well?

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We recommend putting 2 at least vents in SUPs, one in the tail and one mid-to nose area. 

If you are planning to install a bungee hold down system in the nose of the board you can use a vented leash plug and three normal leash plugs as the anchors. 

8. I have seen some people install the fin box and handles first before glassing and some install after the glassing. What to you recommend for a first timer?

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The handles are designed to be installed before glassing (put tape over hole so resin doesn't get it when laminating. When you sand the board as the final step the fiberglass over the handle will be sanded away and open up. 
The finbox should be installed after hotcoating and sanded flush to the board.

9. I want to know if the vented leash plug is necessary for EPS shortboards . I also wanted to know if a vented leash plug works ok on all size of paddle boards (SUPs for surf, recreational, touring and race boards) because of the foam volume.

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Vents are an "insurance policy" for EPS surfboards and SUPs. If the board gets dinged and water infiltrates the foam, heat from being left in the sun or a hot car will expand the water steam and push against the glass causing a delamination or bubble. 

The vented leash plugs are a pressure equalizer preventing delaminations. Very few surfers take care of their boards and are mindful to keep them out of the sun so it is common that unvented boards bubble. We see a lot of that in older SUPs that come in for repair. 

We suggest using 2 VXVs in SUPs to handle the volume of expanding air

10. How should I store finished sup boards. Laying flat but no room , can't stand up because ceiling is 8 ft. So on their side on my old weight bench converted into an sup rack. Will this angled warp the shape of the board

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How should I store finished sup boards. Laying flat but no room , can't stand up because ceiling is 8 ft. So on their side on my old weight bench converted into an sup rack. Will this angled warp the shape of the board

11. The SUP blank is already cut to the specifications on the website? So, if I really wanted to keep it as is then I could glass it out the box without any cutting or shaping?

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The blank comes with the rocker, foil and outline cut. You need to shape the rails and bottom contours to your liking... We can also custom cut the rocker and outline to your preferences, any length you want.

12. How much fiberglass do I need for my SUP?

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The amount of fiberglass depends on length and density of the SUP foam you're shaping, as well as your desired strength vs. weight of the board.

Our Engineered EPS SUP Blanks are stronger than other blanks on the market and require less fiberglass

1 layer bottom / 2 layers deck

Board up to 10' long = 11 yards 6 oz x 42" wide fiberglass

Board up to 12' long = 13 yards 6 oz x 42" wide fiberglass

13. How does the carbon fiber stringer work on the SUP ( is it in the board?)

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The carbon fiber strip is laminated to the bottom of the surfboard or SUP to increase the stiffness so it doesn't bend when standing on it.

Carbon fiber provides great strength when put in tension (the force on the bottom of the board from bending) and is a substitute for the traditional wood stringer.

Incorporating a carbon stringer on the bottom of a stringerless blank eliminates the wood shaping tools needed and fussing with keeping the stringer flush with the foam when shaping, reducing some of the work.

Simply laminate the carbon strip right to the foam and roll the bottom layer of fiberglass right over it and continue laminating the bottom. All in one step...

14. How many vents does my SUP need?

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We recommend putting at least two vents in SUPs, one in the tail and one mid-to nose area due to the volume of foam. (Also applicable to hollow wood SUPS)


If you are planning to install a bungee hold down system in the nose of the board you can use a vented leash plug and three normal leash plugs as the anchors. 

15. I was also looking at your futures SUP handle and was wondering is there a bottom structure to it or is it open. My SUP is a hollow core so an open box would create a problem for me.

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The futures SUP handle is fully enclosed and can be used in hollow wood boards but requires 2 routes (one through, one shallow flange route). A simpler alternative handle is the Factory SUP handle. Regardless of the handle you choose you should insert it into a solid wood block spanning the deck to bottom skins to hold the weight of the board when carried.

16. am interested in a SUP blank. I need it to support 240lbs. What length board would be best to do that?

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We recommend an 11'6" SUP blank for 225 - 250 pound paddlers but can cut any custom size or thickness you want.


Building a SUP is the same process as a surfboard described in our Surfboard Building Guide. We cut the SUP's outline for you already so shaping the rails and glassing the board is really all you need to do.

17. Which fin and fin box do you recommend for a 10’ 6” paddle board. I also need glass and epoxy resin for this board, what do you recommend?

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10.5" centerfin box and a 9" or 10" Centerfin is what you want for a SUP. 


For glassing your board we have 6 oz x 42" wide fiberglass cloth, sold by the yard. It is common to laminate 2 layers on the bottom and 2 or 3 layers on the deck depending how strong you want the board to be.


You'll also need 3 gallons Resin Research 2000CE ULTRA epoxy resin and a 4 oz. bottle of Additive F for your final sanding coat. 


Also, you may want to get a SUP handlevented leash plug, or deck vent plug for your board. 


18. I need a SUP to support 240lbs. What length board would be best to do that?

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We recommend an 11'6 SUP Blank for 200 - 250 pound paddlers. 


the 12'0 SUP Blank is also an option if you want additional float to make paddling easier.


19. Do you have detailed instructions on making a SUP?

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Building a SUP is the same process as a surfboard described in our Surfboard Building Guide. We cut the SUP's outline for you already so shaping the rails and glassing the board is really all you need to do.

20. I'm building a SUP. I've seen some videos showing glassing with 2 layers of cloth. Can I do that with 3 layers or should I do 2, then the third? Your thoughts?

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Laminating 2 layers at a time is the easiest way. The resin will saturate through 2 layers easily but tends to create air pockets when soaking 3 layers at once, making the glass job weaker.


So yeah, do 2 layers and you can immediately roll out the 3rd layer of glass, cut, and saturate it. It will use a bit less resin that way too.

21. I bought 2 of the 11'6 SUP blanks from you guys and have now finish shaping them. I will need supplies for the step to finish the boards.

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1. How much fiberglass clothe should I purchase.  Looks like you guys recommend the 6 oz 3 layers top and 2 layers bottom.  So how much should I purchase to factor in waste as well.  65 linear foot for each board sound about right? Yes, 3 layers deck, 2 bottom. You'll need 20 yards for each board - 40 yards total. Please note we are currently out of stock on the 6 oz x 42" SUP cloth but will be in by the end of this week.

2. How much Epoxy and Add. F should I buy? Does 3 Gallons Epoxy and 2 OZ Add F for each board sound right? or should I get more since there may be a lot of waste for my first try at this? You'll need 3 gallons epoxy per board (6 gallons total) and (1) 4 oz bottle Add F. 

3. If I purchase the FCS SUP handle with Vent. will that be enough ventaliation for the boards or do I need another vent or vented leash plug as well? We recommend putting 2 at least vents in SUPs, one in the tail and one mid-to nose area. 

4. The 10.5 " Center fin Box. does that come with the fin as well? or just the box? Just the box

5. I have seen some people install the fin box and handles first before glassing and some install after the glassing. What to you recommend for a first timer? The handles are designed to be installed before glassing (put tape over hole so resin doesn't get it when laminating. When you sand the board as the final step the fiberglass over the handle will be sanded away and open up. 

The finbox should be installed after hotcoating and sanded flush to the board.

22. Is the SUP handle installed before glassing the deck or after?

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The FACTORY and FCS SUP handles are installed after hotcoating, just like the centerfin box. There are no large forces on the handle so no need for a fiberglass patch over it. Just route a tight pocket and install with resin and cab-O-sil to thicken the resin and decrease drainage into the foam.

23. Using VectorNET and 4 oz S-2 glass on my SUP Shape

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Using VectorNET will definitely improve strength and a good idea. But the 4 oz S-2 glass is only 30" wide and will not lap all the way around the rail to the other side of the SUP. For optimal strength you can use 1 layer 6 oz x 42" E-cloth on the bottom and a combination of 1 layer 6 oz x 42" E-cloth & 1 layer 4 oz S-2 on the deck.

Put the S-2 cloth on the foam and let it cover as much of the rail as it can, then lay the 6 oz x 42" over it.

If using VectorNET on the deck put that on first, then the S-2, then 6 oz....


24. How many vents do I need for my SUP?

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2 vents are recommended for SUPs since there is a large amount of volume in the board. We typically put 1 deck vent about 1/3rd from the nose and a vented leash plug on the tail. Both on the stringer. Make sure to drill the hole in the front deck vent larger than the stringer width so the vent will be exposed to foam on both sides of the stringer. 

25. Can I install vents in the board before glassing like fin boxes?

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Yes you can pre-glass both vents with tape. Make sure they sit about 1/16" high so you can grind them flat after hotcoating. Also watch for air bubbles around the vent circumference when pre-glassing. Make sure there is plenty of resin in that area so you don't have to fill in after grinding. 

26. Would an additional carbon fiber strip on top of the SUP (in addition to the one on the bottom) make the board stronger?

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Carbon reinforcement on the bottom is a must but not needed on the deck. It will certainly make the board stronger and look cool but the gains are minimal. Using VectorNET is a better option on the deck of a SUP as it will strengthen the deck where you stand to prevent foot wells showing up over time. 

27. Do you have a multiplier for rail bands dimensions for a SUP?

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Multiply the railband dimensions from the chart by a factor of 2X for SUP rails.

28. Should two of your vented leash plugs be enough to handle one SUP? My SUP is delaminating.

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Thanks for the email and sorry to hear you are having venting issues in your board. Two Vented leash should be enough to vent a SUP. 


Few things to check:


1. Does the board have a stringer and are the plugs installed on the stringer with the bottom venting area exposed to each side of foam? It is important that internal air can get to the bottom of the plug to vent and a stringer will block the airflow unless the plus is exposed to both sides of foam. 


2. Possibly resin got under the plug during installation and clogged the vent. The epoxy putty "resin dam" included with the plug must be smashed down to spread out against the walls of the plug and foam to seal from resin getting under.


3. You can check the vent by pouring a little water in the plug and as the board heats up and released pressure, you'll see the water bubbling from the vent. 

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