Hello gang. This is the first board that I've made. I have experience with composites in building large model rockets, but it was thanks to the information I learned on this list that I was able to make such a great first attempt. I'm really excited about making more.
The board is 138 x 41 cm made from two layers of 1/4" AirCell Polyester foam sheets from Polyumac. The bottom skin is 3 layers of 5 oz glass with a fabric layer skinned by a layer of 1.5 oz. glass. The top is 4 layers of 5 oz with fabric and skin glass. There is about 4-5 cm of rocker and a single concave on the bottom. The handle is free hand cut from a sheet of 1 inch thick foam and covered with a carbon/glass braided sleeve.
The inserts are 3/8" aluminum that I drilled with a tap hole and back filled with candle wax. After the board was finished I drilled out the wax and tapped the threads in place. I filled the fin support holes with thickened glass filled epoxy and drilled them once the board was complete.
The first step was to lay up the bottom skin and first foam sheet against the rocker table (which I covered with a mylar sheet). Then epoxied the top foam layer in place. Then filled the edges with thickened epoxy and layed up the top glass layers. This filled in the gaps between the layers creating the rail.