After years of watching my brother shred and several more years talking about what a carbon board would feel like it’s time to build one.  Carbon boards exist, they are expensive, stiff, durable, and maybe even good, but we want a project and I would love to see how skills react to layups of known specification.

We are starting with a blank deck without an exterior trim.  This gives us a large curved rectangle dished and with tail bends.  On this first build we decided the top of the deck would provide our critical dimensions with the layup being built off that.  This means the tails slant downward in the mold with the vacuum or pressure pad pressing down on the bottom of the board.

Draft Process:
1.  Seal board with epoxy or paint.

  • leaves a shiny surface in mold
  • may help with release from too

2.  Create tool walls

  • Plastic taped to edge of blank
  • Add draft to all edges.
  • Seal with tape inside/out

3.  Create tool base

  • Primed MDF for easy release
  • Pre drill and screw mdf
  • Make provisions to suspend tool in mold

4.  Pour Tool

  • Mix and Vac Silicon to ensure its free from bubbles
  • Pour silicon until it meets edge of tool

Repeat process for pressure pad.

Load Carbon, Bag, Cure… more to come.
Include 3d geometry within pressure pad
Edge protection from urethane casting


Deck with first seal. Mold box produced from primed MDF. Screwedd and taped with Kapton