Methods of tracing a lengthwise half of a board sports board and applying a substrate film cutout onto the board having the steps of centering a centerline of a tracing scale onto a center of the board, the tracing scale having an off-centerline on both sides of the centerline; aligning a centerline mark of the film with the off-centerline of the tracing scale; flipping the board over such that the board is on top of the film; tracing a trace outline of half of the board onto the film, such that the half of the trace outline is incrementally larger or smaller than the half of the board; removing a release liner from the trace outline to expose an adhesive in the film; wetting the adhesive with a solution of water and liquid soap; flattening the wetted film onto the board with a spreader; and wiping with a wiping cloth.

An improved wooden surfboard and method of construction comprised of pre-cut layers of wood longitudinally arranged of predetermined thicknesses (502-512) stacked and bonded together following the shape of the surfboard. The longitudinal layers include slots (208) to slide and embed multiple transverse ribs (210) in perpendicular direction for joining the longitudinal layers together. The bonded longitudinal layers form a pre-shaped plank with the geometrical features of the surfboard without the need of carving and shaping the surfboard's geometry. A smooth finish is achieved after a light sanding of the pre-shaped plank. In some embodiments the longitudinal layers have predetermined perforations (202) to create air chambers (204) reducing the weight of the surfboard. Other embodiments are as described and shown.

An improved wooden surfboard and method of construction comprised of pre-cut layers of wood longitudinally arranged of predetermined thicknesses (502-512) stacked and bonded together following the shape of the surfboard. The longitudinal layers include slots (208) to slide and embed multiple transverse ribs (210) in perpendicular direction for joining the longitudinal layers together. The bonded longitudinal layers form a pre-shaped plank with the geometrical features of the surfboard without the need of carving and shaping the surfboard's geometry. A smooth finish is achieved after a light sanding of the pre-shaped plank. In some embodiments the longitudinal layers have predetermined perforations (202) to create air chambers (204) reducing the weight of the surfboard. Other embodiments are as described and shown.

A board suitable for riding a wave is described. The board includes interconnected deck and bottom reinforcing zones.

Closed cell chitin foam is provided. The closed-cell chitin foam composition does not absorb water, is biodegradable, and is mechanically characterized by a density range of 16 to 800 kg/m3, closed-cell pore sizes ranging from 50 microns to 1 mm, an elastic modulus of 3 to 175 MPa, and a tensile strength of 0.15 to 6.5 MPa. The chitin is at least 70% acetylated. In one aspect, the foam is enclosed in a shell e.g. in the form of a surfboard. Chitin foam according to this invention is fully biodegradable. The chitin foam overcomes the current problems with foams that contain polyurethane and polystyrene, and which are manufactured from petroleum-based sources. Petroleum based foams are not renewable, have an adverse impact on our environment, and pose significant health hazards to those who manufacture them. The chitin foam with its water-based manufacturing process and naturally sourced chitin, solves these problems.

The present invention includes a surfboard comprising a laminated frame extending along the side rails of the surfboard, the laminated frame comprising three or more layers of laminates, and wherein the laminated frame has been formed to the shape of the rocker of the surfboard. In various exemplary embodiments, the laminated frame may have one or more lateral members extending between opposing sides of the laminated frame, wherein such lateral members may be circular in cross-section, and may include one or more supports connecting the lateral members to the top surface of the surfboard. In various exemplary embodiments, two or more layers of laminates may form an internal structure extending laterally across the laminated frame from one side to the other.

A surfboard includes a core covered with a laminate and having curved perforations in the deck area and the tail area of the surfboard, in order to prevent air blisters from forming between the core and laminate. The curved perforations are deformable under pressure to minimize the opening of the perforations to inhibit liquid from entering and maximizing under zero pressure to allow the maximum amount of trapped liquid and gasses from escaping. The core is formed from an extruded closed-cell polystyrene foam block that has been shaped by restraining it against a shaped form using shaped restraining tools and straps, and heating it; and by cutting using a hot wire. The core is laminated with FIBERGLAS and epoxy resin, and the perforations are formed using a perforating tool that has a planar or curved working surface and one or more heated needles extending perpendicularly from the working surface.

A surfboard includes a first layer and a second layer. The first layer is defined by epoxy impregnated fiber reinforcement fabric configured to cover a rocker and rails and wherein the first layer extends onto a deck at a middle portion of the surfboard and tapers toward a tip and tail so that the first layer does not extend onto the deck at the tip and the tail. The second layer is defined by epoxy impregnated fiber reinforcement fabric configured to cover the deck and wherein the second layer extends to cover the rails at the middle portion of the surfboard and tapers toward the tip and tail so that the second layer covers less than half of the rails at the tip and the tail.

A surfboard includes a first layer and a second layer. The first layer is defined by epoxy impregnated fiber reinforcement fabric configured to cover a rocker and rails and wherein the first layer extends onto a deck at a middle portion of the surfboard and tapers toward a tip and tail so that the first layer does not extend onto the deck at the tip and the tail. The second layer is defined by epoxy impregnated fiber reinforcement fabric configured to cover the deck and wherein the second layer extends to cover the rails at the middle portion of the surfboard and tapers toward the tip and tail so that the second layer covers less than half of the rails at the tip and the tail.

The present invention includes a surfboard comprising a laminated frame extending along the side rails of the surfboard, the laminated frame comprising three or more layers of laminates, and wherein the laminated frame has been formed to the shape of the rocker of the surfboard. In various exemplary embodiments, the laminated frame may have one or more lateral members extending between opposing sides of the laminated frame, wherein such lateral members may be circular in cross-section, and may include one or more supports connecting the lateral members to the top surface of the surfboard. In various exemplary embodiments, two or more layers of laminates may form an internal structure extending laterally across the laminated frame from one side to the other.