surfboard

A brief look on how our boards are built

 
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choosing the right blank is the key

Every blank is produced under our requirements on rocker template, stringers configuration and foam density in order to provide each board with the right weight, the right flex/rigidity and the perfect rocker line.

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Dan Costa

Then each blank is hand shaped by Dan, with over 20 years shaping polyurethane foam and over 4k hand shapes done he still keep is passion alive and the search for the perfect lines is a constant, each board is unique and places a challenge in order to satisfy the surfer needs and desires

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Resin Tints

There's nothing like the beauty of glassing a board with resin tints, this is traditional way where the tints are carefully mix and pour into the board to saturate the cloth

 
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Sanding

After the sander takes its role, leaving everything smooth and even without "burn through" the coat and hit the cloth, the skilled hands once more gives the final magic touch ensuring the perfect curve on the rails  

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hot Coating

The hot coating process is only applied after 24 hours period for the laminated resin cure properly. This layer covers the entire board and even though is looking almost done there's still a lot to do ahead

 
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gloss Coat

Now the final resin is applied now with a different resin specially for gloss and polish for a top end finish 

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Fin placement

This is a critical factor too, sometimes underrated, but where your fin(s) are placed as well the angle takes a key role on the way your board is going to perform

 
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Polishing

Now the word is polish, after being sanded with different wet sandpapers is carefully polish like if we where buffing a classic car.

 
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now it's Finish

After a final check for blemishes the board is clean-up for any leftover of rubbing component and it's finally done and ready to delivery