I got an ePS foam blank from one of the local shapers and laminated a couple layers of carbon on each side (vacuum epoxy).

I was able to get the fins in a couple weeks ago and I'm painting it right now. Which isn't going too well as I dislocated my shoulder. The fin boxes are probox out of Hawaii, really easy to install if you've have a panel router.

Crazy Canuck,

That looks like a ice project - what size and weight is the board?

I have just snapped my third production board in a year and need to get a custom, do you have any links on how to get the vacum bagging process done?

Hope it rides as well as it looks and you get to cut a few nice lines before it dies

Cheers

The board is 6'1" (before I chopped the point of the tip), 1'7", 2.75" and weights in at 3kg on the spot with no finish and fins or tail and front pad probably looking at another 1.5kg or so

I'm not super worried about strength, but I'm a bit worried about flex as it has 400g of carbon on each side and about 600g around the rails

I used to have a link to vacuum bagging but I'm not sure where it went. I envelope bagged it so I didn't have to make a proper jig to bag against. One thing to be warry of when you bag surfboards made of poly of eps foam is that you don't over do it with the presure and crush the foam

...

Such a waist of material, milling all the excess material. Couldn't you get more appropriate blank

If your keen to make your own board this is a pretty good place to start

http://www.surfersteve.com/polystyrene.htm

Edit - If you want to build a greener board try one of these out:

http://www.grainsurfboards.com/boards/surfboard-kits/

Not sure how it would handle kiting but it would look nice