surfboard building
board building
The course offers
a unique opportunity to build your own custom made surf-, kite or skimboard
under the guidance of an experienced shaper. The CERES course goes beyond a board
building workshop by providing you with a comprehensive and exciting
introduction to board shapes, fin technology, composite theory and an insight
into the surf board industry.
The CERES
team places a strong emphasis on environmental sustainability in surfboard
construction and the use of modern high-performance materials to achieve the
perfect balance between performance, durability and environmental impact. You
will have a lot of opportunities to talk to likeminded surfers and share
stories and experiences. And – of course - you will be able to put theory into
practise and surf in (probably) the best conditions in Europe.
do I need to build a surfboard?
No! You
choose how much you would like to get involved. You can build a surfboard, kiteboard or skimboard from scratch to your own specifications,
team up with a friend (or your children!) to build one board together or order
a custom board from our shaper and only apply the finishing touches.
You are also
very welcome to participate by helping other group members and use the in-depth
knowledge gained during the workshops to make the right decisions when ordering
your next board. You will also learn how to repair surfboards.
The course
is essential for people working in the surf retail business who have to
advise customers on hardware purchases and practitioners who have to repair
boards on a daily basis.
customizing your board
When you are
enrolled on the course our team of experts will help you to choose the right
shape and blank material to suit your requirements. We order a high quality
blank from a leading manufacturer and get it machine-shaped to your dimensions
(you only have to apply the finishing touches). Anything can be customised, and
if you are unsure get in contact with us.
You should
think early about your artwork. You can purchase a Hawaiian flower design cloth
for retro-style boards, use Posca marking pens to draw on your blank and/or
sketch a (simple!) airbrush design. We can print multi-coloured logos up to
size A4.
workshop format
The course
will be split in two groups for the workshops. One group will be working in
pairs on one or two boards each. The other group can either start to prepare
their own boards, relax around the pool at the Surf Lodge or go surfing and test
fins. Two members of the CERES team will be with the groups all the time to help you. fast facts
highlights :
Board design
Shaping
techniques
Art work and
airbrush
Glassing
(resin and fibre)
Sanding and
polishing
Ding repair
workshop
Fin tech
workshop
dates :
Spring 2012 tba
duration :
Saturday -
Friday: 7 days
fees :
include accommodation,
all meals, local travel,
workshops, use of power
tools, personal
protective
gear: €790*
*excluding
cost of materials
number of
participants :
8 - 12
activity
level :
Your choice
prerequisites
:
Confidence
in working with
power tools
application
deadline :
Rolling
admissions. Intake
closes one month before the
course starts.
Please contact
us.
course itinerary
Split into two groups. Group 2: Light informal lunch on the beach, rest /
recreational free time (opportunity to go surfing, test different boards, and
explore some new spots). Split into two groups. Group 2: Light informal lunch on the beach, rest /
recreational free time (opportunity to go surfing at our local Aljezur
beaches, or to work on own blank). Split into two groups. Split into two groups.
Day 1: Arrival day
Pick up from Lagos,
arrival at the CERES Lodge, ice-breaking session (coffee, tea, and biscuits),
introduction to the project, presentation of staff and team members, detailed
information about safety measures.
Take delivery of
pre-shaped blanks. Round table discussion on board shapes and on design
features relevant to the first board building step: longboard, short board, fish, stubby, etc. the
effect of bottom contours (flat, concaves, channels), nose and tail rocker, deck
shapes (domed, flat and concaves) and rail shapes (round, tucked under, sharp
edge).
Short drive to local spots around Aljezur to check surf conditions. A catering service prepares dinner at the Lodge.
Day 2: Factory visit : Shaping and art work
Breakfast buffet (cereals,
freshly baked whole-wheat bread, seasonal fruits, free range eggs, locally
produced jam & honey, cheese, tea, coffee, fruit juices, hot chocolate).
Pack-up blanks; prepare packed
lunch (bread, cheese, biscuits, fruit, olives, water, juice), drive to local board factory.
A local shaper explains the layout and
specific features of a professional board building workspace. Demonstration
of shaping techniques.
Group 1: Prepare rails, bottom and deck contour and
surface of pre-shaped blank under the guidance of an experienced shaper.
Prepare blank for art work.
Groups swap activities.
Drive back to Aljezur. Dinner at a nice beach restaurant.
Day 3: Composite theory : Glassing
Breakfast buffet (as on
the first day).
Workshop on composite theory (function of
the core, fibre and resin) and laminating techniques (lay-up, vacuum, resin
infusion). Alternative constructions: wooden blanks, hollow, thermoplastic, foamies and
inflatable boards.
Group 1: Prepare blank for glassing, cut fibre
cloth to size, mix resin, laminate bottom.
Groups swap activities.
Workshop and demonstrations on core materials
used in surf board construction: EPS,
PU, PVC, recycled blanks, EVA foam soft boards, stringer materials, bamboo and
balsa layers.
Group 1: Prepare blank for deck glassing, cut
fibre cloth, mix resin, and laminate deck.
Group 2: Discussion on the impact of surfing and
the board building industry on the environment.
Groups swap activities.
Dinner at an excellent local restaurant.
Day 4: Fin workshop : Fin box fitting
Breakfast buffet (as on the
first day plus freshly baked pancakes).
Workshop on fins I: thruster, quad, single, five fin set ups,
function and placement (cluster configuration, two-in, cant, angles).
Group 1: Mark position of fins, set fin boxes, and
leash plugs.
Group 2: Test drive and evaluate different fin types
and sizes at local surf spots.
Group swap activities.
Workshop on fins II: fin box systems, fin materials and shapes.
Open discussion in the relaxed atmosphere of the CERES Lodge.
Dinner at a great local pizzeria.
Day 5: Resin systems : Hot - coating and sanding
Breakfast buffet (as on
the first day).
Workshop and
demonstrations on resins used in surf board construction: polyester, epoxy,
linseed, uv-curing, pre-preg materials etc.
Split into two groups.
Group 1: Prepare the blank, hot-coat the board.
Group 2: Test different fin types and sizes.
Groups swap activities.
Workshop and
demonstrations on fibre types used in surf board construction: glass, carbon,
dyneema, kevlar, hemp, exotics.
Split into two groups.
Group 1: Start sanding.
Group 2: Test different fins. Discuss and evaluate
results.
Groups swap activities.
Dinner at our favourite restaurant.
Day 6: Ding repair : Sanding and finishing
Breakfast buffet (as on
the first day).
Workshop on board
repair: ding repair, creased boards,
broken boards, delamination, fin box and leash plug replacement.
Split into two groups.
Group 1: Finish sanding and polishing.
Group 2: Production surfboards: demonstration of the
latest surf equipment from a brand distributor. Open discussion on the future
of the surf board industry.
Groups swap activities.
BBQ with fresh, locally caught fish etc. at
the CERES Lodge.
Day 7: Departure day
Breakfast buffet.
Summary and feedback: (examination optional).
Pack up and transport to Lagos.
details and prices
The Board Building course runs for seven days from
Saturday to Saturday. The fully inclusive package covers:
Accommodation in the CERES Lodge; a luscious all-you-can-eat buffet
breakfast (enough to prepare a
packed lunch for a day in the field); evening meals (we take you out to
our favourite local restaurants); expert
tuition and specialist workshops; entrance fees; licenses; all obligatory
insurances; transport once here, personal protective gear (spray overall, gloves, mask) and tool
rentals.
• Certificated • Luxury meals included • Protective gear • Carbon offset contribution
The CERES Board Building course is supported by SeaBase, Future Fins, Prolimit and BIC surfboards.
Material
costs largely depend on the choice of board you want to build. We buy
materials in bulk at trade prices from our partner SeaBase and pass the
full discount on to you. Expect material costs of less than €200 for a short
board build with aircraft-grade epoxy resin, Hexcel glass, F3 fin boxes and a first-class blank.
On completion of the course, you will
receive a Certificate of Participation. Those who want to take things further can take an exam at the end.
introductory price €790 + materials (optional)
We offer group reductions. Contact us for details.
our partners for the board building course
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