SURFBOARD BLANKS

1. What is Engineered EPS Surfboard Blanks?

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2. What is the difference between EPS (Expanded Polystyrene) and Polyurethane (PU) Foam?

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3. What is an EPS blank?

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4. How much does a custom EPS blank cost?

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5. What is a PU foam blank?

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6. How much does a custom US Blank Cost?

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7. What size blank should I get for my design?

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8. Can I buy a stringerless EPS blank and have you guys split it in half and ship FedEX cheaper?

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9. What density foams do you stock?

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10. I am about to shape my first board with my 11 year old son who is doing it for a school project and I wasn't sure what the letter means after the board length, . What does the S, U, and F stand for?

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11. If i buy a surfboard blank do i just need to draw the shape I want and then cut it out?

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12. I noticed your 6'3"EPS blank is similar to the Marko pescado dimensions. I can't tell without a top profile picture, is the nose flat across or already rounded? I'm making a board with a squash nose.

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13. My son is interested in shaping his first board. He's looking for a 6' 2" board and starter kit. He is located in NJ, can you recommend a blank and shapers starters kit?

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14. Would there be a way for me to order a longboard blank made with reverse rocker from you guys so I can shape a noserider?

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15. I am looking to copy a Bing Gold Standard 9-2. I also am going to make an 8-0 funboard and another 5-6 mini simmons. What blanks would you recommend that I order? Also, what fiberglass do you recommend for the longboard?

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16. I had a few questions on the US Blanks. Is the outline already cut-out or does it come as a rectangular piece of foam/EPS

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17. You have stock list for blanks? I'm looking to swing down and grab a handful for a quick batch of short orders in the next week or so.

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18. what is the difference in Foam US Blanks /EPS/ Common Surf Foam

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19. Does it cost $150/185 to ship 1 blank to my house

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20. How to I glue the blank and stringer together? Where do I look for this information?

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21. So you sell skimboard blanks?

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22. Do you sell wakesurf board blanks?

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23. I’ve never used EPS foam and understand that it takes some getting used to. What tools would you recommend? I’ve heard it’s best to use a planer with a drum as opposed to a blade?

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24. I know you guys have a hot wire cutter I was just wondering if you did custom outlines and if so what program and/or file format do you need? What's the cost?

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25. Do I need to vent EPS foam boards?

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26. I'm building a noserider longboard. I understand that increased tail rocker and decreased nose rocker can be helpful for noseriders but was wondering if you had some input.

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27. I have one of your EPS blanks. Before I glass it does it need to be sealed in any way? I have seen different things and just want to make sure. Thanks, I love the blank.

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28. I just finished gluing the stringer and the foam blanks together, it is not perfectly aligned.

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29. Do I need to seal your engineered EPS blanks with spackle?

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30. How would I know which blank to buy, as that is the first important step?

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31. Why is your Engineered EPS foam so special? Is it "super fused"

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32. What kind of glue should I use to glue my blank up?

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33. What is EPS blank "tear out" I hear about?

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34. Need advice for how to fix my stringer and foam glue up. There is a gap between the stringer and foam.

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35. How do I order a custom EPS foam blank?

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36. How do I order a custom EPS foam blank?

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37. Any tips for getting the stringer glue off your fingers?

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38. I am curious which way I should go on the stringer. Foam or wood? Which is stronger and has better resistance to snapping?

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39. When I glued the EPS blank there is a small gap between in the stringer and foam in certain places. Is it a serous issue?

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40. Do I need to spackle my EPS blank?

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1. What is Engineered EPS Surfboard Blanks?

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Consistent High Quality


Greenlight has teamed up with a major plastics manufacturer to design the optimal bead and compression process for EPS surfboards to improve surfboard strength, flex, practical weight, and shapability. We've even engineered the rocker and foils in our blank selection to yield any board you can imagine with the least amount of effort by hand or machine.

Our engineered EPS Blanks can also be customized to any thickness for a super close tolerance blank that requires very little shaping without the expense of paying for a machine shape. 

Greenlight's Engineered EPS Blanks Advantages:

  • Reduced Bead Tear out
  • when Shaping by Hand
  • or Machine

  • Low Resin Absorption

  • Calculated Rocker and Foil Designs

  • Completely Customizable

  • Quick Turn Around Time



2. What is the difference between EPS (Expanded Polystyrene) and Polyurethane (PU) Foam?

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Surfboard are made from (and we sell) two types of foam blanks.


1. EPS Blanks - EPS stands for Expanded Polystyrene. EPS foam is lighter and stronger than Polyurethane foam blanks. It consists of small beads of polystyrene expanded with steam and fused together under high pressures. Greenlight's EPS blanks are engineered with a special bead formula for the optimal strength, flex, and shape-ability of the blank. There is a growing demand for EPS surfboards in the world due to its superior strength to weight ratio. 

The EPS blanks are rectangular in shape supplied with a rocker and foil. You can create any outline shape you want with EPS blanks.

Greenlight is a huge proponent of EPS surfboards and has been developing, manufacturing and selling EPS blanks for over 10 years. 

NOTE: EPS foam must be glassed with EPOXY resin! Polyester resin will melt the foam!


2. PU Blanks - PU stands for Polyurethane. It has been the standard surfboard core for over 50 years. PU blanks can be glassed with either polyester resin or epoxy resin (epoxy becoming more popular due to its superior strength). PU blanks are molded in the general shape a surfboard to reduce the amount of excess foam. Your surfboard shape outline still must be drawn on the blank and cut out.



3. What is an EPS blank?

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EPS stands for Expanded Polystyrene. EPS foam is lighter and stronger than Polyurethane foam blanks. It is also recyclable.  There is a growing demand for EPS surfboards in the world due to its superior strength to weight ratio. 

Greenlight is a huge proponent of EPS surfboards and has been developing, making and selling EPS blanks for over 10 years. We have engineered our own EPS foam that is the only EPS foam specifically designed for surfboards on the market. 

NOTE: EPS foam must be glassed with EPOXY resin! Polyester resin will melt the foam!

4. How much does a custom EPS blank cost?

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We manufacture all EPS blanks here at the shop and can cut up to 12' long. Please email info@greenlightsurfsupply.com with your blank dimensions and stringer option and we'll give you a quote. 

Typically a custom EPS shortboard blank will cost about $70

We can also take a AKU Shaper, Shape3D file or .dxf file you design and cut directly from that.

5. What is a PU foam blank?

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PU stands for Polyurethane. It has been the standard surfboard core for over 50 years. PU blanks can be glassed with either polyester resin or epoxy resin (epoxy becoming more popular due to its superior strength).

6. How much does a custom US Blank Cost?

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We order customs blanks for our customers all the time. Price depends on the blank size and stringer configuration you want. Please email info@greenlightsurfsupply.com for a quote.

7. What size blank should I get for my design?

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US Blanks have a general surfboard rocker and outline. You will need to cut an outline with all blanks that we sell.  When selecting a US Blank you should try to find a blank that fits the dimensions of the board you are trying to shape.  US blanks are a close tolerance blank which mean that the outer part of the blank is the strongest foam and as you get closer to the center the foam will get softer, which makes blank selection critical to the strength of your surfboard. 
EPS blanks are uniform density throughout so you can get one a bit thicker than your finished board dimensions and shape away. EPS blanks are hotwire cut from a block of foam and have a rectangular outline which allows you the freedom of any outline you choose to cut. 

8. Can I buy a stringerless EPS blank and have you guys split it in half and ship FedEX cheaper?

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Sure, we'll split your EPS blank no problem. Just put a note in the order to split the blank.

You can glue it up with a stringer or as a stringerless with Gorilla glue

9. What density foams do you stock?

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Our Expanded Polystyrene (EPS) is available in our Engineered 2# cubic foot density. Other densities (1#, 1.5#) available upon request.

US Blanks we carry RED density & BLUE density for shortboard and midlength shapes, we also carry GREEN density in longboard blanks in addition to BLUE density.

10. I am about to shape my first board with my 11 year old son who is doing it for a school project and I wasn't sure what the letter means after the board length, . What does the S, U, and F stand for?

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We use those letters to differentiate shapes of the same length. If you would like to let us know what you are interested in shaping we can help steer you in the right direction.

11. If i buy a surfboard blank do i just need to draw the shape I want and then cut it out?

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Yes, you will need to draw a template on the board and cut it out to get your desired shape. We offer a selection of printable templates on our site if you are looking to get a pre made template.

12. I noticed your 6'3"EPS blank is similar to the Marko pescado dimensions. I can't tell without a top profile picture, is the nose flat across or already rounded? I'm making a board with a squash nose.

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Our EPS blanks all have square noses and tails so you can make any shape you want.

13. My son is interested in shaping his first board. He's looking for a 6' 2" board and starter kit. He is located in NJ, can you recommend a blank and shapers starters kit?

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Your son should get an "Up to 6'6" Fish, Egg, or Shortboard' or "Up to 6'4" Shortboard" beginner shaping kit. It depends on the type of board your son wants to shape... our 6'6" long kit is designed with extra foam in the surfboard blank to get the feel of shaping without ruining your efforts.

We can ship the kit to your door or you can pick up at our shop if you'd like.

14. Would there be a way for me to order a longboard blank made with reverse rocker from you guys so I can shape a noserider?

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You could use another longboard blank and 'flip" it so the nose rocker would be used for the tail (as long as your outline template fits in the nose area [which would be the tail of the blank when you flip it]) Some guys flip the US Blanks 98Y for nose rider designs.

Or we can custom order you a blank to whatever rocker you want. No problem.

15. I am looking to copy a Bing Gold Standard 9-2. I also am going to make an 8-0 funboard and another 5-6 mini simmons. What blanks would you recommend that I order? Also, what fiberglass do you recommend for the longboard?

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For the 9'2" go with the US Blanks 93Y or 94B depending on the rocker you want to get. I'm not familiar with the Gold Standard rocker but my guess would be the 93Y.
US Blanks 84SP for the funshape and either a US Blanks 510RP or 6'2A for the mini simmons depending on your preference of nose rocker (510 more, 62A less..)
2 layers 6 oz deck / 1 layer 6 oz bottom for the longboard... or if you wanted to keep it lighter for your girl to carry you can do a 6/4 deck.

16. I had a few questions on the US Blanks. Is the outline already cut-out or does it come as a rectangular piece of foam/EPS

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US Blanks have a general surfboard rocker and outline. You will need to cut an outline with all blanks that we sell. When selecting a US Blank you should try to find a blank that fits the dimensions of the board you are trying to shape. US blanks are a close tolerance blank which mean that the outer part of the blank is the strongest foam and as you get closer to the center the foam will get softer, which makes blank selection critical to the strength of your surfboard.

17. You have stock list for blanks? I'm looking to swing down and grab a handful for a quick batch of short orders in the next week or so.

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All our blanks available are listed on our website. Here's a link to the blank page.

We manufacture EPS blanks per order so please give us a few days before picking up. 

We carry US Blanks, Common Surf Foam, and cut EPS in 2.0#, 1.5#, and 1# densities.

Quantity discount pricing is shown on each blank page.

You can order online and we'll have them ready for you to pickup.


Feel free to contact us anytime if you have a question

18. what is the difference in Foam US Blanks /EPS/ Common Surf Foam

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US Blanks and Common Surf Foam are PU blanks (polyurethane foam)

It has been the standard surfboard core for over 50 years. PU blanks can be glassed with either polyester resin or epoxy resin (epoxy becoming more popular due to its superior strength).

EPS stands for Expanded Polystyrene. EPS foam is lighter and stronger than Polyurethane foam blanks. It consists of small beads of polystyrene expanded with steam and fused together under high pressures. Greenlight's EPS blanks are engineered with a special bead formula for the optimal strength, flex, and shape-ability of the blank. There is a growing demand for EPS surfboards in the world due to its superior strength to weight ratio. 

Greenlight is a huge proponent of EPS surfboards and has been developing, manufacturing and selling EPS blanks for over 10 years. 

NOTE: EPS foam must be glassed with EPOXY resin! Polyester resin will melt the foam!

19. Does it cost $150/185 to ship 1 blank to my house

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Please see our Shipping Info Page for different blank shipping costs.

20. How to I glue the blank and stringer together? Where do I look for this information?

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Here's a link to the blank glue up instructional video: https://youtu.be/vcbdzGcQgnU

The video can also be found on each EPS blank product page

21. So you sell skimboard blanks?

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Yes we have foam cutting files for various skimboard sizes. We can provide you an EPS foam blank any length in 2# density. Please contact us for a quote.

22. Do you sell wakesurf board blanks?

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Yes, we have wakesurf board blanks and complete wakesurf board building kits available.

Please click here for our WakeSurf Board Building Section

23. I’ve never used EPS foam and understand that it takes some getting used to. What tools would you recommend? I’ve heard it’s best to use a planer with a drum as opposed to a blade?

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Don’t believe all the hype, EPS is great to shape. A good deal of our customers prefer to shape their boards with it. We all use just a regular planer and do not switch out the blades. We would recommend our Pro Tool series as they were designed to take down foam fast and efficiently, especially EPS beads.

24. I know you guys have a hot wire cutter I was just wondering if you did custom outlines and if so what program and/or file format do you need? What's the cost?

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We use AKU Shaper .brd files, Shape3D .3dx files, or Autocad .dxf files. But you can send a pdf and we can trace it. Or just rocker numbers and we'll create the file for you. No problem.

Cost depends on length, foam density, and stringer material. Send a file over and we can quote it.

25. Do I need to vent EPS foam boards?

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Venting an EPS board is like an "insurance policy" to prevent delamination. EPS boards contain very small air pockets between the foam beads which expand and contract with changing temperatures. If a board is dinged while surfing and water gets in, additional heat (leaving your board on the beach or in a hot car) will cause the water to change phase in to steam and exert pressure on the fiberglass skin - pushing the glass away from the foam (delamination).

It's up you to if you want to install a vented leash plug in your EPS board but we developed the VXVs because so many personal boards were having issues when not vented. Since installing VXVs in boards there has not been a single delam due to water expansion in a board in years. 

*It is highly recommended to install vented leash plugs in stand up paddle boards due to the large volume of foam that will expand and contract more in varying temperatures. All the major SUP manufacturers vent their boards with either a vented leash plug or a deck vent

26. I'm building a noserider longboard. I understand that increased tail rocker and decreased nose rocker can be helpful for noseriders but was wondering if you had some input.

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It is popular to "Flip" a stock blank to increase the tail rocker and lessen the nose rocker. This is also called Reverse Rocker.

 A lot of guys just template the board with the at the tail of the blank if the outline fits.

We can easily build you a reverse rocker blank in any size if your outline templates don't fit on a stock blank that is flipped.

27. I have one of your EPS blanks. Before I glass it does it need to be sealed in any way? I have seen different things and just want to make sure. Thanks, I love the blank.

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EPS blanks do not need to be sealed but sealing helps to use less resin and also provides a bright white uniform surface if you are doing color or artwork on the board. 


You can simply squeegee lightweight spackle on the board (mixed with bottled water to a mayonaise consistency) in a thin later to fill the small holes between the beads, or mix up a paste of epoxy and Q-cell and squeegee that on (makes a stronger board). 


There is also the option of finish sanding the board to 320 grit sanding screen to close up the cavities between the foam beads.

28. I just finished gluing the stringer and the foam blanks together, it is not perfectly aligned.

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The glue up simply holds the blank together so you can shape it. An uneven glue up will just be a little more shaping to level everything out. Glassing the board provides all the strength and the glue is not really a factor in the board.

If you have space between the foam and stringer you can squeeze more glue in. It will expand to fill the gap and is shapeable.

29. Do I need to seal your engineered EPS blanks with spackle?

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Our Engineered EPS foam does not require sealing.

Sealing with lightweight spackle is only used with resin tint laminations to give the blank a flatter surface for uniform color (no darker pools of resin)

30. How would I know which blank to buy, as that is the first important step?

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The answer to your question is covered in detail on the first page of our Surfboard Building Guide. Please read through the guide to understand the entire process and you'll be confident in starting to shape your own boards.

31. Why is your Engineered EPS foam so special? Is it "super fused"

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Our new foam is a consistent density throughout the blank and designed with a special mix of EPS beads that have high energy bond strength that reduces tear out and resin absorption. We could call it super duper fused but it's just marketing words. I've shaped "superfused" blanks that chunks of the rail blew off with one pass of the surform...

The blank rocker and foils are also special since we took a lot of time studying current modern rockers and designed the series of blanks to easily fit just about any board possible.

32. What kind of glue should I use to glue my blank up?

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You can use epoxy resin but we recommend using Quik Cure Gorilla glue as it cures fast and is easy to sand.

33. What is EPS blank "tear out" I hear about?

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Tear out is nothing to "worry" about. It is part of the process of shaping EPS. Our foam is the tightest bead bond in the industry but you will still get some beads that pull out. The idea of shaping EPS to to rip into it with the most aggressive tools to remove the foam them go over it with finer grits of sandpaper or sanding screen to close the small bead voids up. 

If you are painting or doing a resin tint it is advised to apply a thin coat of lightweight spackle on the board to make it a clean, bright white surface to have even color. 

A clear glass job or opaque pigmented resin lamination does not require spackling.

34. Need advice for how to fix my stringer and foam glue up. There is a gap between the stringer and foam.

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No big deal. If you have more Stringer Glue left just squeeze it in the void and it will expand. It's foam too and easily shapeable. If it looks weird you can put a logo over the area, paint the board, or do a pigmented lamination to cover it.

35. How do I order a custom EPS foam blank?

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You can just email the specs of your blanks, length, thickness, nose and tail rockers and we'll draw it for you. 

Or you can send a file from free design programs like AKU Shaper or Shape3D software and we can work with that. 

36. How do I order a custom EPS foam blank?

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You can just email the specs of your blanks, length, thickness, nose and tail rockers and we'll draw it for you. 

Or you can send a file from free design programs like AKU Shaper or Shape3D software and we can work with that. 

37. Any tips for getting the stringer glue off your fingers?

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When the glue is fully cured you'll be able to peel it off your skin. Maybe rub some sandpaper or file on it to break it up. We're peeling glue off body parts all the time here

38. I am curious which way I should go on the stringer. Foam or wood? Which is stronger and has better resistance to snapping?

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Your stringer choice really depends on performance and style. 1/8" basswood stringers have been standard for decades and work really well. Our new HD foam stringers give the board more "pop" out of turns and are just as strong as the 1/8" basswood. The HD foam stringers also give you a choice of color and can be shaped with the same tools as used on the foam. No wood tools needed.

In the end, the snap resistance of a board really depends on the amount of fiberglass you put on the board. An all 4 oz glass board is much more susceptibe to breaking than a board with a mix of 6 oz and 4 oz glass or an all 6 oz glassed board (longboards or old school fish).

39. When I glued the EPS blank there is a small gap between in the stringer and foam in certain places. Is it a serous issue?

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The gap is no issue for strength of the board, the fiberglass shell is 90% of the strength after glassed. To make it look good you can squirt more glue into the gap and let it expand. If you have clamps then use them to pull the foam to the stringer and it will be 100% glued correctly.

40. Do I need to spackle my EPS blank?

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If you're doing a clear, white board or pigmented lamination no need to fine sand. You can leave it at around 80 grit and glass. It will use a bit more resin as the small voids in the foam will fill with resin before the glass is saturated. 

If painting or tinting the resin you can either spackle or fine sand up to 150 screen to close the voids in the foam. Spacking is easier...

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