Surfboard shaper
A surfboard shaper is someone who designs and builds surfboards. The process of surfboard shaping has evolved over the years, and the shaper often tailors his or her work to meet the requirements of a client or a certain wave. Surfboard shapers can be independent or work in collaboration with mass-production companies.
While originally made from wood, most modern surfboards are now constructed from pre-formed polyurethane or Styrofoam EPS blanks. The surfboard is then shaped using an array of tools, including but not limited to the following: surforms, rasps, grinders, sanders, and planes. After the form of the surfboard is sculpted from the blank, the shaper can lay fiberglass or carbon fiber sheets over the top and bottom of the surfboard, and laminate each sheet with a thermosetting substance, such as epoxy or polyester resin.
History
Ancient Hawaiian surfboards
There exists very little evidence that pinpoints the exact location of the first surfboard shaper; however, historical analysis suggests that surfboarding itself first originated in Hawaii. The Hawaiian islanders most likely utilized only three species of tree as the base for their surfboards: the wiliwili, ulu, and koa. After the chosen tree was cut, Hawaiian shapers used sea coral and oahi stones for light reduction; subsequently, the root of the ti plant and the bark of the kukui plant were used for the final burnish of the surfboard. Surfboard shaping was regarded by the Hawaiian islanders as a ceremonial rite; Hawaiian islanders often offered fish to surfriding trees as offerings.Three foundational templates for surfboard shaping were utilized by the Hawaiian islanders: the alaia, the paipo, and the olo. The type of surfboard shape was actually indicative of Hawaiian social structure; the alaia and paipo boards were used by the commoners, while the olo boards were reserved for the royal class. However, the primary distinction between each ancient Hawaiian surfboard shape is their length and weight; paipo boards ranged from 3–6 feet long, alaia boards ranged from 7 to 12 feet long, and olo boards measured up to 20 feet long.
The "hollow board" era
The next technological change in the surfboard shaping industry came with the introduction of the “Hollow Board” by Hawaiian resident Tom Blake. In 1926, Blake acquired an ancient olo surfboard from Honolulu's Bishop Museum; the board was originally 16 feet long and weighed 150 pounds. In an effort to replicate the structure of the olo board, Blake drilled holes in a redwood blank and sealed the top of with wood with sheets of veneer, effectively creating the first “hollow” surfboard. Blake's innovative design drastically reduced the weight of the surfboard, and by 1930, the “Hollow Board” became the first mass-produced surfboard in the world.The "balsa era" and the hot curl board
The advent of the 1930s marks the next technological revolutions in the history of the surfboard shaper. Balsa wood began to emerge as the most versatile base for the modernizing shaper; the balsa wood drastically reduced the weight of the surfboard, and allowed for surfers to move in the water with more speed and agility.The addition of balsa wood subsequently led to the surfboard shaper's move towards the “Hot Curl Design.” By shaving off parts of the tail and shaping the sides of the board, surfboard shapers were able to produce surfboards that allowed surfers to pull into the “curl” of a wave.
Modern construction
The beginning of the 1940s marked the introduction of fiberglass resin, which allowed shapers to construct surfboards that were strong, light, and waterproof. Furthermore, surfboard shapers began to utilize alternate base materials, including both plastic and polyurethane foam. The addition of the new materials as well as fiberglass gave surfboard shapers more freedom and allowed them to incorporate both fins and rocker design in the construction of surfboards.In the 1960s, the design of surfboard began to significantly shrink in size. In the era known as the "Shortboard Revolution", surfboard shapers, most notably George Greenough, Bob McTavish, and Simon Anderson reduced the length of the surfboard, creating a higher level of maneuverability. This innovation serves as the foundation for contemporary performance surfing.
Surfboard shaping today
Currently, many surfboard shapers design surfboards using computer programs and hot-wire cutting machines that expedite the design process, especially in relation to mass-production. These computer programs allow the shaper to create an exacting and reproducible design that can be easily fine-tuned and adjusted.Many professional shapers outsource the highly specialized task of lamination to “glassers”; “glassers” laminate fiberglass to the foam core of the surfboard using thermosetting resins, such as polyester or epoxy. Fins and assorted plugs are usually after lamination, and the final product is sanded and glossed down with buffing compounds and glossing resins.
The surfboard shaper often designs their surfboards based on the specifications of their client; the shaper will adjust the dimensions and concave of the board to tailor to different styles of surfing and various types of waves.