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Pine Cone Designs stencil logo on a striped surfboard rail
Field notes / Project 01B

Old School Recycled Longboard

A 9’0” longboard made out of an old broken board. Shaped and glassed from start to finish using recycled foam with a hand painted stripe design and logo. Bonzer inspired fin setup.

ShapingFiberglassingFinish PaintingFoam Blank

Overview

This board was constructed from a 9’6” longboard that was falling apart. I believe that recycling boards like this should be done much more often. It is a very cost effective way to get ample foam for a board and you're extending the life of the old board, keeping petroleum based foam out of the landfills. This board was shaped by hand and glassed with a custom hand-painted stripe design under the "Pine Cone Designs" mark.

This 9’0” long board has sufficient rocker to be ridden in decently large waves but has enough volume to perform well in small less powerful waves as well. The larger single fin with bonzer inspired side fins make for fun sweeping turns while keeping the board stable and moving smooth.

Process

Shaping was done by hand from a recycled board, followed up with an old school toyota inspired color scheme and design. Full fiberglass layup and a gloss coat sanded to 600 grit left the board with a consistent matte finish.

The main tools used were an electric handheld skill 100 planer, some small hand planes, and a lot of sandpaper. The fins were hand shaped out of walnut, painted to match, and glasses on before the final hot coat.

Gallery

The old donor board strapped to the back of the car Recycled foam blank being shaped with hand tools Fully shaped foam blank on the rack, ready to glass Color test taped onto the blank to check the stripe palette Fresh orange and red stripes, freshly masked with tape Board wrapped in paper with red and blue paint drying Pencil sketch of the Pine Cone Designs logo, rotated to read horizontally Digitized logo in Illustrator Physical cut stencil of the logo, taped and ready Wooden fin blanks held in hand before shaping Test-fitting the orange fin into the fin box Fin glassed in with fiberglass cloth A pencil used to form the leash loop Max holding the finished board in the shop Finished board leaning against the truck Finished board leaning against the truck, alternate angle

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