Back in 2005, I cooked up a nifty way to craft longboard skateboards using resin infusion. This tech was slick but had its quirks: one mold meant one board shape, and the materials? Not exactly wallet-friendly. So, I put on my thinking cap and dreamed up the “Lumberjack Method”—a fun, flexible, and budget-friendly way to build boards.
Project Goals:
- Scalable: A step-by-step adventure that’s easy to tweak.
- Design
- CAM programming
- CNC Machining
- Composite Options
- Wet Layup
- Wet Layup Vacuum Bagging
- Resin Infusion on Core
- Resin Infusion Pre-made Skins
- Graphics
- Finishing
- Assembly
- Flexible: Freedom to whip up unique designs and play with different composite tricks.
- Affordable: Craft high-quality boards without breaking the bank.
This project isn’t just about building boards; it’s a hands-on learning journey. Students dive into CAD to sketch their dream designs, mastering the art of creativity and precision.
Next up, they tackle CAM programming to bring their wooden cores to life with CNC machining. It’s a two-sided machining puzzle that’s as challenging as it is rewarding.
When it comes to composites, the sky’s the limit! Keep it simple with a wet layup, step it up with vacuum bagging, or go all-in with resin infusion. For a sleek finish, infuse composite skins on glass and vacuum-bag them onto the core. Want more stiffness? Throw in some carbon fiber.
The secret sauce to keeping costs low is using affordable core materials. Thanks to stressed skin construction, we can use standard framing lumber for the skateboard’s heart. Pair that with cost-effective composites, and you can skip the vacuum bagging to save on supplies.
I’ve rolled out a bunch of longboards using this method, and it’s a blast! The process offers endless design possibilities, and the boards ride like a dream—springy and responsive in every turn.