The Boards are initially cut from a block of foam with a hot wire. Here, the initial rocker, board thickness and length are considered. It is the rocker, the bottom contour, the shape of the rails and the distribution of thickness that determines the individual characteristics of the board.
Next, the plan shape is drawn on the board establishing the initial width and the board is readied for the shaping room.
The first steps involve cutting the Board's plan shape, installing hi density foam for the fin box, and shaping the bottom rocker and contours. Next, hi density foam is applied to the bottom through a vacuum bag process.
The deck is then shaped and also vacuum bagged with a layer of hi density foam.
After vacuum bagging the deck and bottom with hi density foam, the whole board is re-shaped. The specially design "Lighting Room" and Dave Mel's talents ensure the precision expected of a Custom Board. The foot strap inserts, mast box and fin box are then installed.
Next, the top and bottom are glassed with S-glass and carbon.
And finally, a hot coat is applied to the top and bottom, and the board is sanded for painting.
Then the board receives an urethane primer/sealer coat, another urethane top coat, Stickers and graphics, and a texturing with clear urethane and acrylic dust.
