Happy New Year From The Foam E-Z Family!

2015 has quickly come to a close and with it we are winding down on some of the busiest days we’ve seen here in the shop all year long. This past holiday season has been especially an especially busy one for the team here, which came as a little surprise considering we have been hard at work all year to bring together a whole range of new products and services to our customers. As a result of our busy season officially coming to a head it was necessary for the team to get together and celebrate everything that we’ve been able to accomplish this past year at our annual company Holiday Party a few weeks back at 320 Main in Seal Beach. There was indeed much to celebrate this year too, and as a result a long dinner easily turned into a late night of fun and festivity for the Foam E-Z family.

            Yes, there have been many changes this past year for Foam E-Z, perhaps most notably in the new faces joining the team here in the shop. After saying goodbye to former shop manager Jackson earlier this year, we were excited to welcome new manager Rob Lewis, a former customer and avid shaper, to step in and fill those shoes. Under Rob’s direction, we have been able to expand our line of products and services offered both online and in-store to keep up with latest technology and demand as it becomes available including (but not limited to) a full assortment of colored FCS II fin boxes, Futures new Generation and BlackStix fin series’, and variety of SUP Think Tank goods for those of you out there who prefer to remain more upright out in the water.

            We have also had the pleasure taking part in and sponsoring a whole host of local events which have allowed us to give back to and support the communities that have allowed the shop to thrive for the past twenty-two years.  The event that perhaps had the most impressive turnout was at the Huntington Surf and Sport Surf Demo Day where we had a tent just steps away from some fun surf at the Huntington Beach Pier while we were able to meet and connect with a whole handful of future board builders.

If our recent holiday party serves to be a sign of anything, it was surely a sign of the pure stoke and excitement our team at the shop here has heading into 2016. We have been all been working really hard here to bring a whole slew of new projects and ideas for the shop to life that you should keep an eye out for in the coming months. Among other things you can expect to see an expanded line of products available online and in store, more days available for shape lessons, and the launch of a new monthly blog!

Here's to a happy, healthy, prosperous, and adventurous 2016.  If you haven't already, be sure to Build Your Own Board (BYOB) as your 2016 New Years Resolution.

Thanks for all the support in 2015, see you next year!

The Guys at Foam E-Z

             

Rockers; A Detailed Explanation!

Everyone knows how important rocker is to the performance of a surfboard. US Blanks offers custom rockers at no charge, including private rocker templates.

While our master plugs were designed with a Natural Rocker that fits a variety of designs, we know that individual style and design will require adjustments.

We use the deck line to adjust rocker, and all adjustments are referenced to the Natural Rocker. If desired, we can adjust rocker to the bottom. Adjustments can be made from almost any point on a blank and from one blank size to another. Unless instructed, all rocker adjustments will be made from the center of the blank. If the adjustment is made from a point other than center, the adjustment point will be part of the description. Rockers transferred from one blank size to another will require a match point. Radical rocker adjustments may result in bumps or dips created in the deck line.

Selecting the exact right rocker profile will ensure that you have the perfect contour for your specific board design. Rocker helps determine board speed and turning radius.

Flatter Rocker = More Speed

More Rocker = Tighter Turning

NATURAL ROCKER


All blanks are designed with a Natural Rocker optimized for the widest range of potential design needs. Natural Rockers are written in number of inches that the tip of the nose and tip of the tail rise from the bottom plane of the blank.

The Rocker Formula:

Natural Rocker = Inches Rise in the Nose, Inches Rise in the Tail

(from the Bottom Plane)

Natural Rocker 5 -1/2″N, 2-1/16″T

The Nose is always written first. It begins with the number of inches the tip rises from the bottom plane of the blank and is followed by the letter “N”. A comma separates the Nose rocker from the Tail rocker. Likewise, the Tail rocker is written in number of inches the tip rises from the bottom plane of the blank and is followed by the letter “T”.

ROCKER ADJUSTMENTS


All Custom Rockers are written as adjustments from the Natural Rocker. Adjustments are made from the center of the deck unless otherwise specified.

Rocker Adjusted from Deck Center (the default adjustment)

+1/2”N +1/8”T

This indicates that the tip of the Nose is adjusted +1/2” and the Tail is adjusted +1/8” from the Natural Rocker and the adjustments were made from the center of the deck.

Rocker Adjusted from Location Other Than Deck Center

Adjustments made from a location other than Deck Centered (DC) are indicated by  the number, in inches, that follows the “N” or “T” in the rocker formula.

+1/2”N18” +1/8”T12”

This indicates that the tip of the Nose is adjusted +1/2” from the Natural Rocker, but only within the last 18” of the Nose. And the tail is adjusted +1/8” from the Natural Rocker but only in the last 12” of the Tail.

Rocker Adjusted from Multiple Locations

Rockers can also be adjusted from multiple locations within the Nose or Tail to add subtle rocker to a given area and then increased rocker to another area, (i.e., a “Flipped Tip” effect). This is indicated by simply adding values to the existing rocker formula.

+1/2”N18” +1/2”N12” +1/8”T12”


This indicates that the tip of the Nose is adjusted +1/2” from the Natural Rocker in the last 18” of the Nose and then an additional 1/2” in the last 12” of the Nose. And the tail is adjusted +1/8” from the Natural Rocker but only in the last 12” of the Tail.

AVAILABLE ROCKERS

A drop down menu of all available rockers accompany every blank page listed here  (and in the US Blanks catalog). If you can’t find what you need, we will gladly make you a custom rocker.  We can get your custom
rockered blanks within one week of ordering.  Let us know if we can help!

Thanks to US Blanks for this informative explanation of how rockers are determined.

Father and Son Shape Lesson!

Brad Nadell of Foam E-Z in Westminster, California has long supplied Orange County’s finest shapers and shapers-to-be with everything needed to build a surfboard.  A few years ago Nadell built a shaping bay that would allow first-time shapers the chance to build a surfboard without the investment in tools, space, and perhaps most importantly, under the guidance of a professional.

Recently, Brad’s childhood friend approached him with the idea of building a board with his 12 year old son.  Brad called in world class board builder, Chas Wickwire, to guide the process.  Here’s what transpired.

CHAS WICKWIRE
“My goal is to just provide an overall view of the shaping process.  I put a heavy emphasis on 2 of the main 
building blocks: comfort with the power planer and the geometry building a rail.  I make it as systematic as possible so if the first-time shaper decides to attempt a 2nd board, they’ll have the fundamentals.  The whole process takes about 4 hours and nobody is going to leave as an expert shaper, but we’ll certainly help you avoid a few botched surfboards.”



JAY CAMERON
“Vance is 12 and he’s been surfing since he was 6.  I have a photo of him on his very first wave at San Onofre and to this day he has the same exact style, arm placement, and everything.  Surfing’s been a great bond to share and we surf the same spots that I surfed when I was 12.  Vance was ready for a new board and I thought that shaping would be a very cool extension of that experience.”




VANCE CAMERON
“I just wanted to shape a board that I could ride every day, when the waves are a little smaller and it’s harder to surf my normal shortboard. After talking with Chas we decided to make a 5’10”. It’s pretty thick. Chas suggested we make it a little wider in the noses it paddles easier. And we made it quad.”


CHAS WICKWIRE
“I’ve surfed Seal Beach my whole life so I’m very familiar with the waves that Vance surfs and the goal he’s trying to achieve with this board. We designed this shape with a low entry rocker so it gets into waves really easily, goes fast and is easy to ride when the waves are less than ideal.”  “We used the 6’2” A which is a real versatile blank to shape a 5’10” x 21” x 2 3/8”.”

VANCE CAMERON
“I thought it’d be more fun to shape a board than just go buy one, but I was really surprise how much math is involved. Not just in the fractions with the length and wide, but there’s a lot of geometry. I thought it was going to be more like an art project, but Chas used a lot more math than I expected.”



CHAS WICKWIRE
“Vance was epic. For his age, he had great intuition. If he decided to pursue it, he’d succeed for sure. He looked really comfortable with the tools and allowed the planer to rest properly.”  “We’ve made a lot of great friends in this room and we’re really grateful for share this process with anyone who is interested to learn. I’d encourage anyone to come on out and give it try. “

Thanks to David Scales of US Blanks for coming out and doing the story.

The Art of the Perfect Stringer Curl

Is there anything more gratifying?  When thumbing through Instagram, if you happen upon a perfect stringer curl, it’s a guaranteed double-tap.  It’s a bravo to the shaper who kept his blades sharp, maintained a steady hand, and lucked into some straight grain.

We asked a few stringer curl connoisseurs what’s required to achieve Rapunzel-status.

Firstly, a word from the kingpin of color-dyed plywood:

Bradley Appelcore:  Super straight grain (vertical grain) material, whether from Bass, Cedar, or Redwood performs best.  The straighter the grain without interference from diverging branch grain are guaranteed perfect curlers!  It can be from fast growth (wide grain) or old growth (tight grain) as long as it is arrow-straight. It’s easy to notice on Cedar and Redwood, but much more difficult to spot on the Bass.

Sharp tools are key, low angle, and a steady, even push, keeping your palm out of the way from inhibiting the emerging curl.  There isn’t much you can do if the stringer is from solid wood and has divergent grain (grain rising away from the blank or grain diving into the blank) even with the sharpest of tools.

Essential Tools

Tim Stamps:  The best tool to get the curl is the block plane.  This curl came from the blade from my Lie-Nielson standard angle block plane.  This block plane was a gift to me several years ago from Rich Harbour.  He’s a tool fanatic!

Josh Martin: My vintage Stanley model 60 1/2 block plane is the best tool to get the perfect curl.  I hand grind the iron razor sharp.  Also, my Xacto mini spoke shave is the best for mini curls.

Nick Aleandro:  Each wood will work a bit differently so it of best to have a variety of planes or spoke shaves to choose from with various bevel angles.  I prefer narrow curved Japanese plane since I can use the same tool on the deck and base no matter the rocker.

Massimiliano Purchiaroni:  The tools are very important.  I used a normal David Combi plane, a spoke shave, and a Japanese curved plane.

The Best Wood for the Perfect Curl

Josh Martin:  Premium light Balsa is my favorite wood to get the perfect stringer curl, but it needs to be the good stuff.  The heavier it is, it tends to get stringy and produces the worst curls.  The good stuff produces the most golden and perfectly relaxed curls.  The best part for me is the sound produced when making them.  A light clean hissing sound that almost sings like a rubbed crystal wine glass rim.

Wade Tokoro: Basswood with the David block plane is the best combination.

Breno Basiliro:  Powerline Strignerz is a composite so it is even throughout the length of the board.  You will not run into grains, as with wood, which can break the flow.

Tim Stamps:  From my experience, the type of wood that most often gives the best ‘spiral curls’ is Basswood.  My guess is it’s the combination of the woods density, cell structure, and grain pattern.

Massimiliano Purchiaroni:  Red Cedar is my favorite for a perfect curl.

Todd Messick: Balsa is like Butter compared to the rest. Easy Breezy!

Technique

Wade Tokoro:  One long pass with a sharp blade.

Todd Messick:  The curl comes into play based on function.  I angle my planner to create a roll or curl,  as i cut across the blade.  This technique allows the cut stringer to curl off the side instead of rolling over on top of your pass.  Form follows function.

Nick Aleandro:  Sharp tools are the only option.  At a minimum you should be able to shave with the edge.  When sharpening I go to at least 8000 grit and use a Veritas honing guide to make sure I get consistent results.  What ever your method, a sharp tool and slow cut work best.  It is always better to do a few passes rather than to try to cut one deep one.  If you are digging in often in one section, try approaching from the opposite side or skewing your edge.  Wood sometimes just likes to be difficult, so don’t get frustrated.

Breno Basiliro:  The curl is a reflection of how continuously you’re able to run your hands and make micro adjustments, feeling the board and stringer as you move.  Again, sharp tools are still the most important factor.

Josh Martin:  I customize my plane irons so that they have a slight radius from corner to corner.  This is done so the corners don’t score the foam as much on each side of a stringer but may affect curl quality as well.  Sharpness cannot be over emphasized.  Holding the plane at a slight angle to the grain direction seems to produce the best curls.  Don’t be in a bad mood when making curls.

Tim Stamps:   To get that perfect curl takes three main things: a very sharp blade, a deep cut, and the proper skew angle. I’ve shaped quite a few boards, and these spirals and curls are always things that brighten my day and get me stoked. Just like seeing a perfect wave peel down the beach!

Bradley Appelcore:  I actually carry a tiny cheap Stanley planer with a medium angle that’s 1-3/8″ wide by 3-1/2″ long with a sharp blade loaded slightly on the bias and it works killer.  I have to check the glue line on all production panels so it sees some serious mileage.  However, when I want the kind curl for showing off my fancy stuff on Instagram, I use my grandfathers two handed plane from the 50’s where I can control bias and angle with precision controls.  But that one stays on my workbench.

by David Lee Scales for US Blanks 

One Of A Kind Blank, Two Years In The Making!!!

DEAN EDWARDS

Years Shaping: 48
Board: 5’11” x 20”
Blank: One-of-a-Kind blank made of over 1,000 different offcuts from 47 different colored blanks.  It took 10 years to collect all the foam off-cuts and the process of gluing took over 2 years.

Words by Rick Berman
“For years shapers have been trying to figure out a useful way of disposing the off-cuts of foam left over from shaping a surfboard.  Several years ago, Dean Edwards of Big Rock Color Works, a master shaper/board builder on the island of Hawaii had a vision and began saving the ‘bones’ from the boards he was shaping.  Dean has more than 48 years of experience shaping boards, beginning in the late ‘60’s with Wilken and Natural Progression and through the last 25 years on the Big Island of Hawaii.”

“When he thought he had enough material to proceed, he glued the pieces together and started to shape the BONEFISH.  The advent of colored foam in the last 6 years or so made this approach much more interesting.  Together with the glue lines, a one-of-a-kind blank is produced.  This particular board consists of the ‘bones’ of over 47 different blanks.”

 

Words by Dean Edwards

“I’m pretty isolated here on the Big Island, but I know that other people are building interesting boards.  I had seen the “Sunrise Surfboard” that Jim Phillips made in 2009, which helped me clarify my vision.  Jim’s work is incredible and I just wanted to build something that might encourage or hopefully inspire others to build interesting boards from re-purposed materials.”

“Nearly the entire board is made from waste.  Obviously, the foam is all off-cuts, which normally end up in the dumpster.  The fins were made out of plywood and fiberglass scrap.  The sandpaper was all previously used.  The scraps were collected over the course of 10 years.  There are over 1000 cuts; 90 foam pieces in the checkerboard section alone.  It took over 2 years to glue-up the blank.  There was no template, no rocker. It was all free-hand shaped.  The only new material in the construction process was the resin.”

“One thing that I’d like to reiterate, is that there are so many ways to reduce the waste we create in our industry.  The Bonefish is an example of something that would have ended up in a landfill.  With a little consideration, we can help reduce our waste output.  That is my challenge to other surfboard shapers.”

Young Costa Rican Girl Rips and Shapes Her Own Board!

Shaper: Surya Folger
Age: 10 years old
Years Shaping: 1/2
Number of Boards Built: 1
Location: Playa Negra, Costa Rica


Forest Folger (Surya’s Dad)
Surya’s been surfing since she could walk.  She competed in her first contest at the age of 6.  Previously, she was riding a 4’8” Rusty Kerrosover, but I wanted to get her on something a little different.  I really liked the outline and flat rocker of this Craig Anderson model Hayden Shapes that I was riding, so I tried to replicate that board in a much smaller version.  This board is a 4’6″.  It’s a very user-friendly design, for both the shaper and the surfer.






So much of our life in Costa Rica revolves around the ocean.  There is nothing better than water time with your kids.  This experience of shaping a board with Surya and then using it in the ocean just adds another dimension to the experience.  It’s really inspiring to see her begin to understand how shaping a rail determines the lines that she can draw on a wave.  It’s a really cool learning experience for us to share.  Plus, she did a great job with the board.  She’s made every contest final since she began riding it!

Surya Folger
I prefer to shape my own board, rather than buy one.  I really enjoyed making it.  It’s fun to try something new and then ride it in the ocean.  The board is so fun because it’s easy to turn.  It’s very loose.  My favorite spot to surf it is called Piko Pequeño.  The paddle is easy and when you get a wipeout it’s smooth.  The board works really good there.
            

I was going to leave the board white, but then I saw a Yin-Yang in a magazine and I decided to paint it on my board.  With that design, it looked like it needed color so then I added the pink, yellow, and green.  My dad helped me paint it.  That’s my favorite thing about surfing too, it allows you to express yourself in your own unique way.  It’s really fun!

EPS FOAM: Superfused (molded) VS Block Cut (Slab)

In addition to the traditional polyurethane foam blanks, US Blanks offers 2 two types of EPS foam blanks: SUPERFUSED and BLOCK CUT. This article is designed to help distinguish the differences between the two.

EPS Billets and Molded Blank

KEY TERMS: 

EPS: EPS is an abbreviation for “Expanded Polystyrene”. Expanded Polystyrene is a type of foam, sometimes referred to as Styrofoam. US Blanks uses EPS to produce surfboard blanks. It is regarded as lighter and more buoyant than traditional polyurethane foam. It cannot be used with polyester resin due to chemical reaction sensitivity. Epoxy resin works ideally with EPS foam.

Epoxy: Epoxy is a plastic-like resin used as an alternative to polyester resin in the construction of a surfboard. It can be used with both EPS and PU (polyurethane) foam blanks. Epoxy is lighter and stronger than traditional polyester resin and emits 50-75% fewer VOCs (volatile organic compounds) than polyester resin.

 Polystyrene is one of the world’s most widely used plastics. It’s made into a variety of forms including foams such as expanded polystyrene, also known as EPS. EPS is a closed-cell foam, made up of tiny, hollow, spherical beads. In fact, EPS is made up of 98% air which is the reason behind its lightweight. Common uses for EPS are packing applications (foam peanuts, ice chests) and construction applications (insulation, void filler). EPS is inert and non-toxic, both to the environment and one’s health. Styrene is naturally occurring in many common foods such as fruits, coffee, cinnamon, and beef. Further, EPS is completely recyclable.

EPS Beads

EPS used as surfboard blanks began to emerge as a viable option for surfboard shapers in the mid 1990’s. At the time, Clark Foam dominated the market with their wide variety of polyurethane foam blanks which stemmed the growth of EPS. While the epoxy resin used with EPS blanks was both lighter and stronger than traditional polyester resin, the boards were more expensive to build, had problems with yellowing and were difficult to repair.

Those obstacles, however, were overcome and popularity for EPS blanks grew after the closure of Clark Foam in 2005. Quality polyurethane blanks were temporarily difficult to procure so shapers were required to consider alternative materials. Epoxy technology also improved with cleaner formulas, varying densities, and more controlled flex patterns. All of these factors contributed to the increased acceptance and performance quality of EPS blanks.

EPS blank usage is growing, but still accounts for a relatively small percentage of the surfboard  blank marketplace. It is currently the preferred foam for Stand Up Paddle boards and Wake Surfboards.

US Blanks offers two types of EPS foam:

EPS foam is made from a fusing together of small, pre-expanded foam beads. The key difference between SUPERFUSED & BLOCK CUT EPS is the fusion process.

Slab Cuts

BLOCK CUT (Slab Cut)

For BLOCK CUT, the beads are fused into a large block (3’x4’x24’). The blanks are then custom cut from the block into a specific size, shape and dimension surfboard blank. This process offers extreme versatility in blank size options. Unused EPS foam scraps are 100% recycled. 

SUPERFUSED (Molded)

SUPERFUSED blanks are fused into a pre-cast mold of a designated surfboard blank size, i.e., 6’5” or 7’2”, etc rather than the large block for the BLOCK CUT. While this limits versatility to the number of pre-cast molds, it allows for smaller beads to be more tightly fused and thereby produces a finer finished surface. The resulting foam more closely resembles the tight cell structure of traditional polyurethane foam. 

Key Points: 

BLOCK CUT allows for superior versatility in blank options. SUPERFUSED allows for tighter cell structure and fusion properties.

Molded (left) Slab Cut (right)

EPS FOAM RECAP

Key Benefits: The main benefit of EPS is that it is 100% recyclable. Additionally, it is lighter than polyurethane.

Performance and Flexibility: Performance and flexibility are matters of subjectivity and preference. EPS is lighter and more buoyant than PU. Both of those elements can allow the surfer to ride smaller, lesser volume surfboards which may, in turn, help performance and paddling. The flex properties are certainly different than PU. It is the responsibility of the shaper to determine the board dimension and stringer configuration that is best suited for their client’s needs.

Construction: The construction of an EPS surfboard is basically the same as a traditional PU surfboard. The foam core is shaped into the desired dimension and then wrapped with fiberglass cloth soaked in resin. The main difference is that one must use epoxy resin, as opposed to traditional polyester resin that is used with PU foam. Construction costs are slightly higher for EPS than PU boards.

Surfboard Stringers, The Possibilities Are Endless!

Stringers have been an integral part of surfboard construction since the introduction of polyurethane foam in the late Fifties.  Previously, solid wood surfboards had plenty of strength, but also a lot of weight.  The introduction of polyurethane foam allowed for surfboards to be much lighter, but also more fragile.  Early polyurethane surfboard builders glued a long piece of wood (often redwood or balsa) in the center of polyurethane foam blanks and coined the name “stringer”.  The stringer added strength to the foam blank and just enough flex and recoil to increase the surfboard’s maneuverability.  The wood stringer has remained a vital part of surfboard construction over the past half-decade.

While a single piece of wood down the center of the blank is considered to be the traditional surfboard-stringer configuration, many successful variations have been implemented over the years.  Every stringer configuration offers performance dynamics unique to a given board design.  When choosing a stringer configuration, a surfer should consider three main factors: strength, performance and aesthetic.

Every wood type has a unique level of hardness and flex, which will correspond with a board’s strength and stiffness (in regard to maneuverability).  Further, given a specific board design, offset stringers, curved stringers, or parabolic stringers would all create a different distribution of energy than a traditional straight, centered stringer.

While stringer configuration is an important part of a board’s performance dynamic, it is no more vital than foam density, rocker selection, fin placement, glassing schedule, or a myriad of other design elements.  A good shaper will be able to assist the surfer in deciding which materials and designs will best suit their needs.  The surfer, however, should have a frame of reference for communication with the shaper.  

Below, you will find a list of the various stringer options.  The stringer configuration offerings are only limited by one’s imagination and we are happy to fulfill custom orders.

US BLANKS IN-HOUSE MILL

The US Blanks in-house mill allows us to offer any variation of stringer thicknesses and configuration.  Some limits are set by the length or width of wood available.  Their red cedar comes 6” wide and will not fit all rockers, and the poplar plywood has a length limit of 8′.

They offer 7 types of stringer material, 4 types of raw wood and 3 additional offerings.  A description of each follows.

Basswood - Fine straight grain with an even texture. Creamy white in color and medium weight. Relatively soft.

Red Cedar - Straight grain with medium texture. Reddish brown and highly aromatic. Lightweight and soft with high durability.

Cedar Alternative - Sourcing consistent and reliable Cedar is increasing difficult and expensive to procure. The cedar alternative offers similar shape-ability and aesthetic as cedar.
Balsa Wood - Very soft, lightweight, yet strong, with a course, open grain and bright yellow/beige color.

4mm Unidirectional Poplar Ply - They offer three versions of Poplar Plywood; Basic, Team Ply, or High Performance Ply. 

Applecore Stringers - Appelcore Stringers are comprised of three plys of 1/24th inch basswood laminated together. The lamination adds strength and consistency to the stringer. Further, Appelcore Stringers are available in a range of 6 color options (wherein, the basswood is dyed).
Powerline Stringerz - Powerline Stringerz are a wood alternative, made of a 4-ply non-woven polymer. It is lighter and stronger than wood and impervious to water. It cuts easily with hand tools and on shaping machines. It is colorless, but reflects and embodies a chosen glue color.

PVC - PVC is a wood alternative. It is a plastic, available in 3mm and 4mm, colored red or white. It offers plenty of flex, but less strength than wood.

STRINGER CONFIGURATIONS

Center Cut - A single piece of wood in the center of the blank.  This is the most common and traditional stringer arrangement.  Any type of wood can be used.

Multi's - 2 or more stringers in any configuration.  Any type of wood can be used.  Many variations of Multi-stringers have unique names, some are more widely known than others.  Off-Set is a commonly used name for any number of stringers located away from the center of the blank.

Flared - Flared stringers begin in the nose or tail and curve to exit along the rail.  Any distance, angle, curve or wood type can be used.

Wedge - Wedge cut indicates the wedged-shape aesthetic of the stringer cuts, but there are a number of different ways to achieve this aesthetic.  Varying styles of wedge-cuts are known by nicknames and clarification is often needed when ordering.

A wedge configuration is made with 2 pieces of wood, starting close together, perhaps touching, and then separating into a “V” on the other end.  Any degree of separation is acceptable.

“Model A” refers to a wedge cut that begins close together in the tail and separates in the nose.  ”Reverse Model A” refers to a wedge cut that begins close together in the nose and separates in the tail.

Wedge cuts can also include Multi stringers, T-Bands, and any stringer material.









T-Band - A T-Band simply refers to 2 or more stringers that are laminated together. Any type of material or thickness is acceptable. 

Parabolic - Consisting of 2 stringers, the name refers to the shape of the stringers. The two stringers are bent and follow the contour of the rail of the surfboard, one on either side. The desired function is a faster return to static post flex.  With a strengthened perimeter, the surfer can apply a more controlled weight to the board’s rail, thus gaining more controlled buoyancy. The added flexibility on the perimeter of the board allows the surfer to lean into the stringer as opposed to the foam. This flexes the stringer and recoils the surfer out of the turn as it flexes back which equates to more speed, acceleration and torque through each turn.

Colored Foam Inserts - US Blanks offer a variety of colored polyurethane foam and can insert wedges, halves, or straight cuts between stringers. 

POLYURETHANE FOAM - Definition and History

POLYURETHANE FOAM

“PU” foam, as it’s known, has been the predominant material used in surfboard construction for more than half a century.  The goal of this article is to share the history and lineage of our product and aid in the understanding of the material that is at the core of our surfing experience.

KEY TERMS:

Polyurethane: Polyurethane is a plastic, which in the case of surfboard construction is used as a foam.  Polyurethane foam is the most common type of surfboard core.  It is usually wrapped with fiberglass soaked in polyester resin to finish the board’s construction.

Polystyrene: Polystyrene is a plastic, which in the case of surfboard construction is often intended to reference Expanded Polystyrene, also known as EPS.  Expanded Polystyrene is a type of foam, commonly known as Styrofoam (although Styrofoam is a brand name owned by the Dow Chemical Company).  US Blanks uses EPS foam to produce surfboard blanks as an alternative option to polyurethane foam.

Mold: In regards to surfboard blank construction, “mold” is defined similarly to other plastics industries.  It is a hollow cavity in which polyurethane is poured.  The polyurethane foam expands to fill the capacity of the cavity and hardens.  The polyurethane foam is removed from the mold and the resulting form is a surfboard blank.

Blank: “Blank” refers to the foam structure from which one shapes a surfboard.  Surfboard blanks are made in a variety of shapes and sizes intended to closely meet the shapers requirements of a desired surfboard, thereby not wasting an excess amount of foam.  The blank roughly resembles the contours and shape of the finished board.

HISTORY

Polyurethane was first used in 1937 by Otto Bayer in Germany and quickly found applications during World War II where it was used in aircraft construction (coating and insulation).

Prior to commercial polyurethane surfboard production and working out of his garage in Pasadena, California, seminal surfboard designer Bob Simmons (who introduced fundamental design elements of nose-lift, foil, and sculpted rails) first began experimenting with polystyrene foam as a surfboard construction material in 1947.  He made “sandwich” boards constructed of a polystyrene core sandwiched between two planks of balsa plywood with hand-shaped balsa rails enclosing the design.  Simmons learned that polyester resin dissolves polystyrene on contact so the plywood kept the volatile components from meeting.  He then sealed the design with fiberglass.  During the summer of ’49 Simmons partnered with local Malibu surfers Joe Quigg and Matt Kivlin to sell more than 100 “sandwich” constructed surfboards.  This construction method outlined the building blocks for modern PU surfboard construction.

During the early 50’s polyurethane was being a used in common household items, like insulation in refrigerators.  Dana Point surfer and board builder Whitey Harrison successfully cooked a polyurethane blank in his barn in 1955, but never attempted larger production.  In 1956, brothers Dave and Roger Sweet found success selling polyurethane blanks in Los Angeles, but lacked the precise designs that would aid shapers in fully embracing the new material.

Hobie Alter

Meanwhile, reliable balsa wood supply was dwindling, which prompted shaper Hobie Alter and his glasser, an engineer named Gordon “Grubby” Clark, to switch their entire supply of surfboard material from balsa to foam.  The pair invested in a secluded factory in Laguna Canyon, where they designed a mold that would create a blank in two halves, divided lengthwise.  The halves were glued together with a wooden stringer.  The design was finished with fiberglass and coated with resin.  By the summer of 1958 the foam and fiberglass construction had secured its place as the premier performance surfboard in California.

The new technology was widely embraced by surfers, but the popularity of the movie Gidget in 1959 greatly increased America’s fondness for beach lifestyle.  Alter and Clark were perfectly positioned to accommodate the new demand and they quickly established Hobie Surfboards as one of the leading names in surfing.  In 1961 Clark bought Alter’s share of the foam production business.  The split was amicably, and Gordon Clark officially established Clark Foam.  The business moved to Laguna Niguel in 1964, and by the end of the decade Clark had the lion’s share of the world surfboard blank market.  With his engineering background and a keen business sense, Clark made endless improvements to his production line and portfolio of blank offerings.  He accommodated the ’60s surfing boom and held a steady grasp of his paramount position as the world’s lead supplier of surfboard blanks for the next 41 years.

Gordon Clark

After the closure of Clark Foam in late 2005 two former key Clark employees partnered with two industry veterans to form and launch US Blanks in early 2006.  US Blanks redesigned many popular blanks sizes and used their sizable team of highly experienced, former Clark employees to produce consistently high-quality polyurethane blanks on a large scale.  US Blanks additionally offers EPS foam and, over the following 7 years, has secured their position as the world’s leading supplier of surfboard blanks.  As of 2013, polyurethane foam is still the most widely used core for surfboard production.  US Blanks manufactures a water-blown, Isocyanate based Polyurethane foam.

US BLANKS PU FOAM

US Blanks manufactures a water-blown, Isocyanate based Polyurethane foam.  Polyurethane surfboard blanks can be glassed with either polyester or epoxy resin, making it versatile in terms of giving riders more options.  Polyurethane foam is regarded as easier to shape than other types of foam.  It is also slightly less expensive than Expanded Polystyrene.  US Blanks offers PU blanks in 6 varying densities, 9 foam color options, and over 50 different blank sizes and dimensions.  Each blank is cut and glued to order, to the client’s specific rocker and stringer requests.  Thousands of rocker adjustments are available to choose from or custom adjustments can be accommodated.  US Blanks’ in-house mill allows for almost any conceivable stringer configuration to be incorporated into any surfboard blank.  The result is a completely customizable surfboard blank that Foam E-Z can get for the customer in one week!.  US Blanks is also the only polyurethane surfboard blank company manufactured entirely in the USA, from their facility in Southern California.

Rockers And Bottom Curves, Natural Or Custom!

“Rocker” is the dimensional curve along the bottom, top, and rail of the surfboard, usually referenced from nose to tail.  Not one rocker is universally better than another.  Rocker is just one instrument in an orchestra of design elements that contribute to a successful surfboard shape.  There are, however, some basic rules of hydrodynamics that one must consider in order to understand the function of rocker.

Ace Buchan uses every bit of his rocker to make this steep drop!

Firstly, the more rocker or bottom curve that a design has, the more maneuverability but less speed the design holds.  The added degree of rocker pushes water, and consequently reduces overall speed.  On the other hand, that added curve allows the design to turn in a tighter radius.  Additionally, rocker allows designs to fit into steep waves without submerging the nose, i.e., hollow waves like Pipeline.

Conversely, flatter rocker brings more speed but also a decrease in maneuverability.  The flatter rocker allows more of the board’s surface to be in contact with the water and therefore generate more planing speed.  Generally, flatter bottomed designs are applied to boards that will be surfed in small or gutless waves, i.e, fish boards.  And, of course, with the flatter, straighter rocker the board will feel more stiff and will be more difficult to turn.

Cut and ready to glue up

US Blanks are molded with a “Natural Rocker” unique to each blank and specified in the blank description within their catalog.  The Natural Rocker is designed to accommodate a variety of designs.

While the blank is molded with a Natural Rocker, there are two additional opportunities to adjust the rocker before finishing the surfboard design.  Once, when the blank is ordered and secondly, when the shaper is shaping the board.

Each blank can be ordered with any desired rocker adjustment.  The blank is cut down the center lengthwise, stringer is chosen and the blank is glued with the rocker adjustment in place.  The adjustments are written in a formula beginning with the nose (noted with an “N”) adjustment and followed by the tail adjustment (noted with a “T”).  Us Blanks use the deck line to adjust the rocker which is referenced from the Natural Rocker, i.e., an adjustment of +1/4”N -1/4”T would indicate bending the foam upward to add one quarter inch of rocker to the nose and then bending the tail downward one quarter inch to decrease the rocker in the tail.

US Blanks has a large selection of Public Rockers available to choose from, specific to each blank, but we (Foam E-Z) can also accommodate "Custom Rockers" at no additional charge.

A few of US Blanks Public Rocker Templates!

Once the blank is ordered with the requested rocker adjustment, the shaper can still make further refinements to the rocker of the final surfboard design.  The shaper can carve subtle adjustments to the board’s rocker within the design of the given blank, but they cannot permanently bend the blank at this point.  This is why blank selection is an important first step.  It provides a flexible yet specific foam structure that most closely resembles the final design that the shaper will implement.

It is important to remember that the resulting affect of any rocker adjustment is influenced by other design elements like rail contours, fin set up, and concaves.  Finding the exact right rocker for a surfer, a given board and specific type of wave is the result of thorough communication between the surfer and the shaper.

Thanks to US Blanks for this thorough explanation!