Wakeboards are made with lots of time, energy and experience which is greatly needed to develop and manufacture a superior wakeboard. The process in which wakeboards are made is not “cut and dried” at all. Instead, it is art and engineering in equal parts — just a broad overview of the process here.
Wakeboards Are Made By Creating The Perfect Wakeboard Mould
The wakeboards are made in a long and laborious process. The first step is to create the perfect mould, but it is essential as it defines the finished board’s features. Every aspect of this part of the process is informed by trial and error. The actual production of the wakeboard can begin once the mold is finished.
The Foam Core of The Wakeboard
The centre of most quality wakeboards is a two-part resin polymer. Each material is inserted into the mould separately, but the two chemicals bind to each other after “mixing and fixing” and form a surprisingly strong but flexible foundation on which the rest of the board can be formed.
Prepping The Wakeboard
There are quite a few rough edges on a resin-cast wakeboard, as one might imagine. Currently, there are no machines able to finish the process, so all superior wakeboards are hand-finished. The first step is to remove and fill any extraneous holes with the excess resin that has leaked out of the mould. To prepare it for the next step of production, the surface of the foam core board is then sandblasted.
Sheets of fibreglass are then cut in unique patterns when applying the fibreglass. These sheets are then laid and coated in resin on top of each other. The accumulation of many sheets, often as many as fifty, builds up a particular “profile” that will be added to the board later on. It is this profile that gives its specific surfing features to each wakeboard.
Adding the graphics: Advertising their product by including name identification on the board is an important detail for the maker. On the surface of the board, a thin layer of plastic with the name of the maker and some aesthetic elements are now laminated.
Moulding The Board To Hold Everything Together
The foam core, the fibreglass sheets and the graphics are all incorporated in this phase as the board is given its final form. A little bit of heat and a little bit of pressure builds the final form of the board until the individual elements are combined.
Finishing The Wakeboard Ready To Use In The Water
Multiple sanding, buffing and polishing repetitions are involved in the rest of the wakeboard construction process. It’s not unlike waxing a car, but it takes a lot more practice and skill. Don’t forget to remember the time and effort that went into its formation the next time you ride one of these beauties.