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How 2 Make a Wakeskate
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WWSA
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Joined: 09 Oct 2003
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PostPosted: Jul 24, 2004 7:00 pm    Post subject: How 2 Make a Wakeskate Reply with quote

I had a few guys email me about how I had made my decks, so i thought it might help to make a topic on how I made mine.

First off you need 2 know that it will cost you almost as much or more as a manufactured deck. But if you plan to make more than one it gets cheaper.

First I built a Mold or a Jig to laminate my 1/8 sheets together

look at pic

2 make the mold
we took a 2x12 8feet long cut it in half
now with one of the 2x12's you need to draw out your rocker
On this mold i used one of my wakeboards
2 draw out your rocker you stand up your2x12 on its side then lay your board on 2 bricks the same size (one at each end) then slide the 2x12 next to your board and trace out the rocker

Cut out your rocker and trace it on the other 2x12 cut it out as well
look @ pic

frame the little ones together and then the bigger ones (like a ladder)
look @ pic


the mold is 4ft x 2ft wide so we took a 1/4 in sheet of plywood and covered the sides of the mold (where the rocker is).
look @ pic

Now that your mold is done they should fit togerher pretty good.

Now you are ready to start on your deck

Go find a tightly grained 1x8 sheet of wood (birch is what i used) It depends on how many plys you want your deck, you should get 4 plys out of a 4x8 sheet

draw out the size of your mold (4x8)on the sheet and get as many plys as possible out of your sheet. NOTE it helps to have the grains crossing so try and cut the second sheet in a diff way.

Take your 2x4 sheets and get them stacked with the grains going East 2 West on one and North 2 South on the next back to E 2W and so on.
Save the best looking one for the bottom of the board make sure that the wood grain is on the top and the bottom all of the layers n between don't matter.

2 Laminate
Now take them all turn upside down. leave the bottom of the deck face down. spread epoxy ( i used a fiberglass resin) top 2 bottom of each one (one at a time) and stick them together
Look @ pic mixing epoxy

Now you put them in your mold and clamp it down (real hard) i recommend about 10-12 clamps ( went and got more)
look @ pic

Let dry over night pull out and start shaping the board to the size you want.

This will make your flat deck If you want to make it with some contour on the top like a cassette you will have to measure and cut out some 1/8 wood out of your sheet ( you will want to do a stair stack them)

look at pic

epoxy them together on the board and clamp them down let dry over nite

unclamp and start sanding, and sanding even more sanding
Note if you are going to have fins Drill your holes first then sand

You will want to seal it with somthing I used a vynlester epoxy spray on with a gun. It works well and drys real fast in the sun Like 5 Min so you can do coats real quick. Make them real light (the coats)

go out and ride if you any questions just reply or more pics of the project I have lots.




mixing epoxy.JPG

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mixing epoxy
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bottom of mold.JPG

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bottom of mold
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half of mold.JPG

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framed together
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rocker.JPG

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rocker
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mold or jig.JPG

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This it the first Mold that Brian and I made
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Jaysin Smith
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WWSA
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PostPosted: Jul 24, 2004 7:01 pm    Post subject: Reply with quote

the pics work from bottom to top sorry and a few didnt take i will see if i can put them in
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Steven M
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PostPosted: Jul 24, 2004 7:11 pm    Post subject: Reply with quote

can you please explain more on the concave part
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WWSA
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PostPosted: Jul 24, 2004 7:15 pm    Post subject: kolb Reply with quote

here is some that didnt take



bottom.JPG

 Description:
pretty
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kolb ready.JPG

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done sanding
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just epoxyed.JPG

 Description:
need 2 sand
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clamped down.JPG

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clamped down
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top of the kolb.JPG

 Description:
top of board
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PostPosted: Jul 24, 2004 7:16 pm    Post subject: Reply with quote

WaKeSk8er209, look at the last bunch of pics see if that helps if not I will go in 2 mor detail
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PostPosted: Jul 24, 2004 7:20 pm    Post subject: top of board Reply with quote

here is the top after griped



griped.JPG

 Description:
griped
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PostPosted: Jul 24, 2004 7:34 pm    Post subject: routed Reply with quote

On the concave part I stacked from all directions to get the router look on the edge of the board. I did this because the board was already shaped. I know now that you should put the concave parts on b4 you cut on it at all. By doing this you can stack them from the center of the board out and make it flush all the way around the edge of the board. Then you get a router with 45 deg angle and route all the way around the board after you shape it Look at this board it was routed



little board.JPG

 Description:
routed little board
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PostPosted: Jul 24, 2004 8:13 pm    Post subject: Reply with quote

damn i dont think i have the patience or handy skills to build one of those. those boards are seriously awesome, the washers on the fin screws look like they would get in your way. and those fins are huge but... good job
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PostPosted: Jul 24, 2004 8:27 pm    Post subject: Reply with quote

ya, i see what you mean by the "stairway" thing.

im gonna build me one soon.

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PostPosted: Jul 25, 2004 9:45 am    Post subject: Reply with quote

yes they did get in the way and the fins are big. I am old school

Now i use a bit that drills the wood down a bit and makes it where the washer and nut fits flush with the top of the board

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PostPosted: Jul 25, 2004 1:24 pm    Post subject: Reply with quote

the concave looks weird and super deep but other than that thats a sick board, is the rocker 3-stage????
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WWSA
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PostPosted: Jul 26, 2004 7:57 am    Post subject: deck Reply with quote

yes it is

And its not 2 deep must be the pics

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JankyZep
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PostPosted: Jul 28, 2004 7:52 pm    Post subject: Re: How 2 Make a Wakeskate Reply with quote

WWSA wrote:

Go find a tightly grained 1x8 sheet of wood (birch is what i used)


What do you mean by 1x8? That is really small, did you do it in little squares or what?
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PostPosted: Jul 28, 2004 8:01 pm    Post subject: Reply with quote

janky he probably ment 1/8" sheet of wood.
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PostPosted: Jul 28, 2004 8:47 pm    Post subject: Reply with quote

hey that shits purty pimpin but mine i mad rail fins and glass them in next time try it, its so much easier if your good with fiberglass work like i am, that way the bolts wont get in your way other than that it looks rele good i like the concave system u designed for it i think i might but it on my next board which will be soon at the rate that im goni wit breakin boards on my kink up rail, mad props to u for makin yourself one, not many people do, they take the easy way out and pay about 125 more than us!!!!!!! try classed in fins u wont catch on the bolts beta for mad trickz!!!!!!!!
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Morphine
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PostPosted: Jul 28, 2004 9:36 pm    Post subject: Reply with quote

I'm an idiot and I STILL don't know what you just said Smile
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WWSA
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PostPosted: Jul 29, 2004 9:14 am    Post subject: Reply with quote

1/8 of an inch sheet of plywood not 1x8

Late.....

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PostPosted: Aug 09, 2004 1:05 pm    Post subject: Reply with quote

what who said
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PostPosted: Aug 09, 2004 5:47 pm    Post subject: Reply with quote

i think he means what "DownSouthRider" said
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PostPosted: Aug 10, 2004 7:26 am    Post subject: Reply with quote

10-4
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