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By jlongmuir in OutsideSkateboarding

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Introduction: Comprehensive Longboard Guide

By jlongmuir
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About: Hello my name is Jordan Longmuir, I am 18 and studying a bachelor of Information Technology specialising in Network Security. I have always loved pulling things apart and seeing how they work, which has made... More About jlongmuir »

Pacific Northwest Woodworking Showshow to Pacific Northwest Woodworking Shows for Hello my name is Jordan from Sydney, Australia. I''s final result. In this guide I will attempt to cover all the details including pre-production, longboard press designs and production, constructing the longboard and finishing the longboard.

This DIY project cost approximately AUD$100 which is cheap as longboards range in price between $120 - 299. Plus the longboard press is reusable and there will be leftover timber to make a second board.

This instructable is a work in progress. I will continue to update it and add any tips and tricks I pick up. Please leave feedback.
I appreciate it. Thanks

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Step 1: Longboard Design

For this build I am basing the longboard on a Loaded Dervish longboard. This is because the board has a simple shape and design. I have made several boards with my own designs as well and will make reference to that in this guide.

When basing a longboard on a preexisting board, I have found the best way to make the design is with Photoshop. I have a separate instructable on making a Photoshop longboard cutout. Check out the link below

https://www.instructables.com/id/Making-a-Photoshop-longboard-cutout/

Step 2: Materials - Longboard

The Longboard is constructed from layers of plywood, glued together to form the deck. These layers of ply are 3mm or 4mm and are placed in alternating vertical and horizontal pattern, this forms a strong deck that has neither too much vertical flex or horizontal flex.

Selecting the right plywood is very important as there are various grades and types. The first is the grade: The grade is the quality of the face ply which ranges from D to A (D being the lowest quality and A being marine ply). An A grade ply is good for either the top or bottom face as it looks the best. Plywood comes in non-structural and structural plywood. 4mm Marine AA plywood is structural and 3mm BC plywood is non-structural. BC plywood is good for the middle layer as they are not seen. I used mixed hardwood plywood because it is cheaper and more accessible then birch or cedar plywood.

The other important part of making a longboard is choosing the right glue. The main glues used are PVA woodworking adhesive, Polyurethane adhesive and Epoxy adhesive. PVA is cheap but not waterproof which makes it not ideal and Epoxy is the strongest and the most expensive but make the board very stiff which is not always what longboarders want. I used polyurethane adhesive because it is not super expensive, waterproof and is very strong but it does leave the board with some flex.

The final component of the longboard''s life and helps prevent damage.

To make the board you will need:

- Plywood Structural Bc 2440x1220x3mm (I paid A$16.50)
- Plywood Marine Aa Grade 1220x810x4mm (A$10.98)
- Adhesive Polyurethane Sikabond 125g (A$7.22)
- Diggers 0.25m² Fibreglass Repair Kit (A$20.95)
- Feast Watson 250ml Gloss Clear Varnish (A$15.60)

I live in Australia and bought all the requirements from Bunnings Warehouse. The links to the material at Bunnings are below.

http://www.bunnings.com.au/plywood-bc-premium-2440x1220x3mm_p0340267
http://www.bunnings.com.au/plywood-marine-aa-grade-1220x810x4mm_p0320033
http://www.bunnings.com.au/adhesive-polyurethane-sikabond-125g-m-purpose-techgrip-418051_p1660985
http://www.bunnings.com.au/diggers-0-25m-fibreglass-repair-kit-no-1_p1565863
http://www.bunnings.com.au/feast-watson-250ml-gloss-clear-varnish_p1520126

Step 3: Materials - Bolt Longboard Press

To make the longboard the plywood must be pressed to achieve the intended shape. There are many forms of presses but I use a Bolt press. The bolt press comprises of a series of horizontal wooden clamps or (ribs) which are screwed into a frame. To make this Longboard the press has these requirements:

- 3m Pine Structural F5 70x35mm A$4.98 (3m standard size)
- 5.4m Pine Dar Fj 42x18mm (2x2.7m) A$8.10 (5.4 standard size)
- Zinc Threaded Rod 36x1/4in x3 A$9.60
- Nuts Hex Half Zp Zenith Snppk 1/4 Pk30 A$3.32
- Leg Furniture Acc Leggz 1/4x5/16in T Nuts Pk4 x2 A$3.96
- Zenith timber screws 6g 30mm pk35 A$3.48

I bought all the requirements from Bunnings Warehouse. The links to the material at Bunnings are below.

http://www.bunnings.com.au/pine-structural-f5-70x35mm-l-m-radiata_p0051348
http://www.bunnings.com.au/pine-dar-fj-42x18mm-2-7m_p0220010
http://www.bunnings.com.au/threaded-rod-zp-macsim-36x1-4in-whitworth-63sz0143_p2410278
http://www.bunnings.com.au/nuts-hex-half-zp-zenith-snppk-1-4-pk30-eba1006_p2420258
http://www.bunnings.com.au/leg-furniture-acc-leggz-1-4x5-16in-t-nuts-pk4_p3940070

Step 4: Bolt Longboard Press - Cutting List

The first step is to cut all the components out. To cut the timber I used a power drop saw and to cut the metal rods I used a metal handsaw.

Cut according to the cutting list below:

- Pine Structural F5 70x35mm - Cut into 9 30cm lengths
- Pine Dar 42x18mm - cut 2 100cm lengths
- Pine Dar 42x18mm - cut 9 30cm lengths
- zinc Threaded Rod 36x1/4in - cut 18 15cm lengths

Step 5: Bolt Longboard Press - Building the Frame

The tools required to build the frame are a drop saw, tape measure, tri square, pencil, power drill and 7.5mm drill bit.

To build the press frame start by finding the centre of both main rails, screw the centre rib to the middle leaving 5cm on either side of the centre rails. Screw 2 timber screws into each main rail (meaning 4 screws per rib).

Leave 71mm between each rib, once all 9 ribs are screwed in, the total length of the press is 95cm which is the length of the longboard's design.

The next step is to drill 7.5mm holes at the ends of the ribs. Find the centre of each end and measure 1.5cm inwards, mark with a pencil. This is where you will drill the hole. Once all the holes are drilled you are ready to make the wooden bolt clamps.

Step 6: Bolt Longboard Press - Building the Rib Clamps

To build the rib clamp you need to draw a profile into the ribs to bend the plywood. This longboard will have a 1/2"" camber. The concave of a longboard is when the sides of the longboard bend up allowing your feet to get good grip on the longboard. The camber is the upward bend of the deck between the trucks. On a flexible board this ensures that the rider will always be sitting higher than the trucks and gives more leverage for turning.

You need a pencil and ruler to draw the profile as well as 3 nails and a hammer.

The first thing to do is to draw a centre line through all 9 ribs.

To incorporate the 1/2"" camber. The other ribs from the outside in slow rise to meet the centre rib. Each rib is drawn 3.1mm higher to reach 12.5mm. Refer to the second picture.

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