Everything On The Inside... Brought To You By US Blanks (Pt. 4: Stringer Selection)

If you’ve been following our “Everything on the Inside” series, you’ve learned how to select the right foam, density, and blank size for your build. Today we’ll explain your stringer options.The stringer serves 3 main purposes in the surfboard;

            1) Strength

            2) Flex

            3) Aesthetic

With stringer selection, there are no right or wrong choices. Each choice is simply a matter of preference. 

US Blanks offers over 30 different stringer materials and an endless number of “glue-up” configurations, and while most surfboards are built with a stringer, it is in fact, completely optional. Both EPS and PU foam blanks can used to make stringerless surfboards. 

Before we proceed with stringer options, a quick word about the manufacturing process. All US Blanks begin as stringerless foam. All stringers must be glued into a cut blank. All blanks are custom cut and glued to order. US Blanks has an in-house mill, so they can cut and glue-up nearly any conceivable configuration. 

 US Blanks offers 5 solid woods; (Balsa, Basswood, Dark Wood, Cedar, and Redwood), various ply-woods, one   composite (PVC, in red, white, and black), or high-density colored foam.

Each stringer material type has it own rigidity (strength), flex characteristics, and aesthetic. Gluing wood together into plys (or “t-bands”) adds strength and also allows the shaper a unique aesthetic. US Blanks in-house mill allows for wedges, multi-stringers, or curved options such as flares or parabolics. There really is no limitation to the combination of glue-ups available. If you can dream it up, US Blanks can glue it up.

Just keep in mind, as with all surfboard design elements, what you acquire in one area, you may sacrifice in another area, i.e., increasing strength will likely decrease flexibility. Finding the exact balance of strength and flexibility with your desired aesthetic will be your challenge. But rest assured, US Blanks has every possible option available to you.

The endless options can be overwhelming, so as a starting point and a source of inspiration, below are some examples of various glue-up options. 

Stop by the shop or give us a call at 714-896-8233 to order your custom stringered US Blanks today!

Blue High Density Foam T-band

Everything On The Inside...brought to you by US Blanks (Part 2; DENSITY)

In Part One we discussed foam selection, and helped to delineate the differences between Polyurethane foam and EPS foam, as well as the differences between Block-Cut EPS and Superfused (molded) EPS. In Part Two we’ll discuss the various densities (sometimes referred to as “weight”) available for each foam type. As surfboard design and surfing styles have developed, US Blanks has engineered different foam densities to accommodate each need. 

“Density” = Pounds-Per-Cubic-Foot of material (foam) for a given space (the blank’s dimensions). 

            When Gordon Clark and Hobie Alter began producing polyurethane foam surfboard blanks in the mid 50s, they designed their foam for be a similar weight to the wood logs that surfers were accustomed to riding. The heavy foam boards were very sturdy and stable, but difficult to maneuver. As surfer’s skills developed, Clark provided lighter foam, which surfers were able to turn more easily. This trend towards lighter-weight foam continued up until the late 90s, where Kelly Slater, et al., ushered in very thin, narrow, highly-rockered shortboards. These boards allowed for the emergence of aerials, fin-releases, and 360s, but also saw a much greater incidence of board breakage, due partially to the lighter foam, but also the higher impact maneuvers. Since the late 90s, foam density trends have diverged into a wide range of needs. The current “ride anything” ethos requires that shortboards are available in either lightweight or Tow-weight, longboards to be built for high-performance or as throwback logs, as well as any manner of single-fin, kneeboard, asym, funboard, SUP, Gun, and even multi-foam constructions (PU & EPS).

            As with any aspect of board building, what you gain in one area, you will lose in another. Lighter weight foam will offer more maneuverability, but inherently less strength. The loss of strength can be mitigated by other construction materials like stronger stringers, carbon fiber, thicker glassing, and stronger resin, etc. 

            To ensure the exact right foam for any build, US Blanks offers (6) density options for PU blanks, as well as (2) density options for EPS blanks. For PU, the weight is identified by the color on the nose of the blank. Due to a few variables in the manufacturing process (mold compaction, skin-to-core ratio), exact PCF (pounds per cubic foot) for PU foam is not given. Rather, a stock weight (Blue) is designated and then all other densities are referenced from that weight, as a percentage of either more dense or less dense.

From Lightest to Heaviest:

- Orange Density (Competition Weight) is approximately 12% to 13% lighter than Blue. This would be most commonly used for elite level professional shortboards.

- Red Density (Performance Weight) is approximately 6% to 7% lighter than Blue. This is a common selection for a surfer who wants more performance from their shortboard, midlength, or longboard.

- Blue Density (Stock Weight) is the basis for comparison. Blue is the perfect combination of weight to strength ratio; light enough to maneuver, yet strong enough to provide extended use.

- Green Density (Cruiser Weight) is approximately 9% to 10% heavier than Blue. This is a common selection for classic longboard and funboard designs.

- Brown Density (Classic Weight) is approximately 30% to 32% heavier than Blue. This is a common selection for traditional log-style longboards. 

- Black Density (Tow-In Weight) is approximately 205% heavier than Blue. This is almost exclusively used in shortboards designed for tow-in surfing.

EPS Blanks (both Block-Cut and Superfused) are available in two densities; 1.5 pcf & 2.0 pcf. 

Ultimately, there are some fairly simple standards that you can follow (i.e., shortboards should generally be Orange, Red, or Blue. Longboards should generally be Red, Blue, Green, or Brown). Most performance characteristics in the water will be determined in the shaping bay by contours, rocker, fin setup, etc. but selecting the appropriate foam density is key to having the right foundation upon which to build.

For further information, please reference: http://usblanks.com/blank-options/density-selection/

Foam E-Z fuNKy FieldTrip To Stamps Surfboards

I recently took a little skateboard trip down the street to visit Tim Stamps of “Surfboards by Stamps” fame.  When I rolled into his shop, he was glued to his lap top computer getting ready to watch Brett Simpson surf his heat in 

Intently Watching

the Burton Toyota Pro at Newcastle Australia.  Knowing Tim needed some support,  I pulled up a seat next to him and watched as Brett unfortunately didn’t get the waves needed to move through his third round heat.  

That’s the life and relationship of a pro surfer and a shaper to top ASP surfers.   Tim has been making boards for Simpo for the past few years.  After the heat was over, and a quick “F” bomb, it was back to work in the shaping bay.  Stamps had some deadlines to fill before he left for the Gold Coast of Australia.  He headed down under to support his other big named ASP surfer Courtney Conlogue as she surfs in the Quiksilver Pro. 

Simpo Boards

As I entered Tim’s shape room we chatted about some of the tools and the nuances of the different abrasive grits he uses.   Tim has been integral in helping us develop our line of shaping tools.  He comes to us with ideas and I go to him for feedback and testing before we launch and tools.  This way we know that what we sell works and we can stand behind it.

Stamps’ boards are made completely in house from the shaping to the glassing.  He employs some of the best guys in the industry to do his glass jobs and uses only the best materials.  By having it all under one roof, this insures that Tim’s boards are exactly to spec before leaving his shop.  Quality control  at its best!  Tim is a true craftsman, having learned his trade from one of the best shapers around - Rich Harbour.  

Fine Tuning

If you haven’t had a chance to ride a Stamps board, go check one out, or just tune into any ASP contest to watch Simpo or Courtney tearing it up on one.

GlassRoom

Thanks again for having us and we are rooting for Simpo and Courtney in the Quiky Pro!

The Sound of Dust, Short Film About Tim Stamps!

Hey Cyber friends, we have a treat for you today! Our long time friend and customer Tim Stamps of Stamps Surfboards has a new short film, "The Sound Of Dust".  This cute short film gives us all a little insight into what it takes to be a professional shaper in this industry, as well as his love and dedication to his craft. The guys over at Hidden Notice did a great job creating this vid and keeping it real, honest, and personal. Check it out and show Stamps some well deserved love! 

Congrats Tim!

Tom's Creation Plantation DVD In Stock!

We just got this bitchen video in we're totally stoked on it.  It's got some great surfing, interviews, scenery, and great information on building Alaia's.  We have had a few of Jon Wegener Alaia Pawlonia Blanks in the shop and plan to have more coming up this summer.  Let us know if you're interested in building an Alaia and we'll supply you with the right Pawlonia wood from Jon Wegener.

From filmmaker Cyrus Sutton (Under the Sun and Riding Waves) comes a look at the Alai’a surfboard resurgence and the creative world of surfboard builder Tom Wegener.  With an innovative half surf film/ half shaping tutorial format,TOM’S CREATION PLANTATION shares Tom’s story while giving you the working knowledge to build your own Alai’a. Shot on location in Australia, Hawaii and California,this DVD pack features a surf film highlighting Alia’a surfing, an instructional in which Tom Wegener walks you through the steps of shaping your own Alia’a and a bonus piece in which his brother Jon goes over the essentials of Alia’a ding repair. Also included is Tutorial booklet, so you have a reference while shaping, as well as a postcard featuring imagery by Cyrus Sutton.



Tom Wegener and his brother Jon have opened the door to surfing’s future by reintroducing the Alai’a, an ancient wooden surf craft devoid of fins, foam or rocker. Alai’a surfers are redefining performance surfing with critical tube rides, long sweeping cutbacks and drifting 360’s while displaying a grace and flow that is unique to this friction-free craft.

Are You a Super Shredder?

I only have one questions for you, "Are you a super shredder?" Masayoshi Takanaka is, and here's the video to prove it. We here at Foam E-Z like fun, interesting, weird, and progressive surfboards. I'm not sure how this board will surf with a big hole in the middle of it, but it's pretty rad to see the craftsmanship that went into this instrument of the ocean and stage. I personally prefer less nose rocker, but then again, I can't wail out a tune on my surfboard like Masayoshi can. Enjoy!

Citrus Shapes - Cool article off Korduroy.TV

Citrus Shapes

Daniel and Curtis are two childhood buddies who grew up surfing San-O, Church, and Lowers together. At 23 years old, fresh out of college, and into the “real world,” the two got inspired and decided to make their own shaping room…and they got all their materials for FREE! Here’s there story:

First off, what was the inspiration behind the “free” shaping room?

We were inspired by our buddy who is a shaper in Morocco. He taught himself how to shape by watching a video and now he makes boards for professional Moroccan surfers. He started running his business with a low budget and he had to get creative due to lack of resources. This showed us that quality/creative boards can be produced if the effort is willing to be put forth, even on a low budget.
Where did you manage to get all of the materials for free? Who donated the land space?

The supplies for the shaping tent were an accumulation of generous people and getting creative with our resources. It started with needing a roof over our heads. We didn’t know where to even begin, but realized that we needed something because it was November and if anything was going to happen in the middle of winter it had to be done in some sort of shelter. Daniel’s dad, Randy, had generously offered us an old outfitter’s tent that he and Daniel used to take camping every year. It is 20 x 16 feet, so we figured that would be plenty of space. Then we needed a place to set up shop, so Curtis’ dad, Rick, generously offered us a place to build our tent… not sure how pumped his mom is on the huge eyesore in her backyard now. Then the floor was built off of old pallets donated from Daniel’s old plumbing boss and the lights from his pops. Lastly, a majority of our tools were given to us by a family friend, Stan, who has shaped in the past. Stan also gave us tons of advice in getting started, he is a man to be listened to because of his expertise in building sail boats. So everything needed for the shop was free… HUGE!

Seems like a pretty cozy situation with a fireplace and all. Where did you get the idea for adding in a fireplace? Any other unique features of your setup?

Yeah we needed to keep it cozy and we figured that it would help us stay warm in the middle of winter. It keeps things a little interesting due to the fact that we are working with flammable chemicals with a blazing fire, all inside a small tent. But it’s all good!

How long did it take you to put everything together?

We were able to build the whole thing in a couple of days thanks to Curtis’ dad. He saved us hours of backbreaking work by leveling the dirt out with his tractor. Then the tent took us about 30 min to set up, the floor took a day, the racks a couple of hours, and presto, the Shred Shed was born!

How many boards have you made so far? What kind of boards?

We have each made one so far and have started another. The first boards were both 5’8” single-fins. We decided to do massive diamond tails. Curtis did a slight v-bottom and Daniel wanted to keep it as flat as possible to see how much speed he could get. We are just wanting to build the boards that we imagine in our heads. We are excited about experimenting with unique shapes and having fun riding them.

Where would you suggest one to look when wanting to learn how to shape, build their own shaping room, etc.?

Just be honest with people about how little you actually know and ask questions. What helped us out was talking with guys that had experience. People were pumped on our ideas and our desire to make different types of shapes, so they would give us as much advice as we wanted. We also must give credit to JC and “Shaping 101.” A must for anyone starting out. A huge help came from the videos that you, Korduroy, shared with us: Shaping Room, Shaping Blocks, etc. Lastly, find a best bud to share the experience with!

What do you find to be the most difficult part of shaping? What about the difficulties of glassing?

The hardest part of shaping is staying clean… the stuff gets everywhere! Also with our first boards we wanted to take our time so we used no power tools. When we finished shaping we had some serious arm-pump from the surforms.

As for glassing, is like working with a time bomb, before you know it it’s too late. Most of the frustrations came in this part of the process. What you thought was a great shape can turn into a disaster within a blink of an eye. It was a fun process and we learned a ton from it. It is amazing how much detail is involved to get a perfect glass job.


What has been your favorite step of the process…besides surfing the final product?

There were so many nights where we both didn’t want to close up shop because we were so pumped on how things were turning out. Every step of shaping gave us so much stoke because we were seeing this ugly block of foam begin to turn into something that looked like a surfboard. This started out as a project to see what we could create, little did we know how much fun we would have with it!

Do you feel like you have found a new hobby to take serious or is it just something for fun every now and again?

We have fallen in love and are actually planning on building many more boards. Between the two of us there are so many things we would love to shape, it is just hard trying to figure out what will be next. Right now we are starting to work on some shapes for a trip to Costa Rica. For now we are stoked on shaping our own boards, but who knows what might happen in the future.

Do you have a name for this project?

Yup, the name is Citrus. We decided on this name for two reasons. One, we are shaping in the middle of orange groves and two, we hope this project produces some good fruit for all enjoy and take part in.

For anyone that is interesting in following us on this adventure, check out our blog at www.citrusshapes.com or Facebook.

Also, if you have any questions about what we are doing or just want to drop a line and say hey, email us at citrusshapes@gmail.com

Thanks Korduroy for all the help. Keep the stoke coming!!!

John Peck - The Penetrator Breaking On Through To The Other Side!

Thanks to the guys at Korduroy.TV for putting together this awesome video of John Peck. It is a great representation of John, a man who has always lived on his own terms. We first met John Peck back around 1994 when he came into Foam E-Z to buy a blank for the Penetrator he wanted to make at the time. He since visits the shop from time to time get a blank or a tool. Each time he shows up he exudes an incredible sense of peace about himself. Anyone who has met him will know what I am talking about.

From being credited as the first to surf real Pipeline in 1963, to one of the most extreme proponents of mind-altering substances in the psychedelic seventies, John Peck has always been exploring the boundaries of his existence. He has been exploring ways to optimally ride waves for over 5 decades and it's this research that has lead him to refine his Penetrator longboard design. In this episode of Korduroy's All Yew series, we learn about the evolution of the Penetrator and how John approaches the board creation process.

"HARBOUR CHRONICLES, A Life in Surfboard Culture" Book Signing & Auction

Honolua Surf Co. Presents "Harbour Chronicles: A Life in Surfboard Culture" Book Signing & Auction, Thursday April 8th from 5-8pm.





Inspired by the life and work of master surfboard shaper, Rich Harbour, this 144 page, full color hard cover book includes essays by Mike Marshall (RIP), C.R. Stecyk III, Steve Pezman and Mitchell De Jarnett. Rich Harbour and many of the other contributors to the book will be here signing copies so don't miss this opportunity! A limited quantity of books will be available at this event for the retail price of $29.95. The publication includes many heretofore unpublished, historic photographs by Rich Harbour, Peter Brouillet, Leo Hetzel, Leroy Grannis, and Sean Collins. There will be a number of special guests present to sign books!

At this event, a silent auction will be held for the special quiver of 'Museum Edition' Surfboards designed by Rich Harbour especially for this show. In addition, a Limited Edition (#3 of an edition of a only five! ) 50th Anniversary Harbour Surfboard made of Curly Redwood / Balsa will be included in this charity auction. The Surfrider Foundation and OCC Frank M. Doyle Arts Pavilion will benefit from the proceeds of this auction so please come bid on a piece of surfing history, support responsible stewardship of our coastal resources, and the arts at OCC as well. Rich Harbour has been shaping since 1959 and has crafted more than 29,000 surfboards. Vintage Harbours are sought by collectors around the world who are eager to own a board handcrafted by one of surfing's greatest living board builders. Rich still works every day, sculpting these exquisitely crafted surfboards in the oldest continuously operating shape room at 329 Main St. in Seal Beach, CA. After 50 years of shaping, he remains a vital influence on the art and design of the modern surfboard.

I have briefly seen the book and it looks awesome. There are incredible pictures and stories throughout this hardbound book. I've heard quite a few of the classic stories over the years and were involved in a number of them when I was grom. Hope to see you there I know it will be a great event. Brad

PRO SHAPER INTERVIEW with Mike Minchinton by Grant Ramey

Recently I had the privilege to sit down with long time Huntington Beach shaper Mike Minchinton. Mike is a pretty legendary dude who has worked with some notable guys like the late Chris Hawk, Carl Hayward, and Robert August just to name a few. I remember being eleven years old and going into the old Roberts August shop on the corner of 5th st. in Huntington Beach and seeing the Minchinton Model board. At that time I had a beat up old mini long board that paled in comparison to a gloss polished, air brushed beauty. I had a little ritual that lasted about a year that went like this, surf, go to Robert August Surf Shop, stare at boards, eat, surf, and then go back to R.A. to look at the Minchinton Model. That's my little bit of history in regards to Mike. I'm sure it's a familiar story, just insert your name and the shaper's name and you have your own experience.

Listen to the interview:

Nice Article in the Daily Pilot - Newport Beach newspaper

Dawn Patrol: Foam E-Z eases shaping experience

By John Burton

Updated: Friday, January 8, 2010 12:10 AM PST
My friend Kathy Escher has a teenage son, Kole, who surfs and she tells me about interesting things like a place where you can shape your own surfboard.

Foam E-Z near the Westminster Mall is a one-stop shop for any and all materials needed to make or repair surfboards. For professionals or do-it-yourselfers they have everything, including a shaping bay with all the tools, accessories, and help required to make your own board.

I had to check that out so I dropped by and was greeted by Grant Ramey. I introduced myself and explained why I was there.

“So, do you want to shape a board and write about it? he asked.

“Err, uh, me? Shape a surfboard?” I stuttered.

I hadn’t considered that. There are some things you inherently know just aren’t your strong suit and for me that includes making things with tools.

“Yeah, that would be cool,” I heard myself say.

So the game was on. It’s a busy place and Grant had customers so I cruised around the shop. A few minutes later, Foam E-Z’s proprietor, Brad Nadell, arrived and we talked for a while.

He started the business in 1993 as an alternative source of foam blanks for shops that had a hard time meeting the minimum orders required by Clark Foam, which for many years held a virtual monopoly.

Clark’s stunning decision to abruptly close up shop, and the repercussions still felt throughout the surfing industry is a story in itself, but Nadell had to adapt and change the business dynamic. Today their focus is more toward the hobbyist and outstanding customer service is their edge.

Brad helped me pick out a blank for my first effort. He steered me toward a “second” which works just fine but has a cosmetic flaw. They cost a lot less and are a good idea for novices.

He and Grant told me that coming up with a template for drawing the outline on the blank is an important first step. I went home and flailed unsuccessfully, so when I returned for my shaping session I used one of my boards and their templates to make the outline.

Then I had to cut out the shape with a hand saw. I did an OK job although there were a couple of wrinkles.

The next step was truing things up using a Surform plane. Luckily I had Grant as a consultant or it would have been a disaster.

I started removing material from the top and bottom using a planer. None of this is easy if you’re not used to it and the planer can do some damage so I went back to the Surform and some heavy sand paper.

That’s as far as I got during my first session. I came away with something that looks more like a surfboard than a coffee table so I’m calling it a success. There’s a lot more shaping to be done so we’ll see how it turns out.

I have a new appreciation for the skill that went into my custom made boards. My Foam E-Z experience was great — drop by or look up www.foamez.com.

Daily Pilot article