The board-in-a-box kit includes everything you need to build a hollow wooden surfboard (excepting the tools). It is supported online with hundreds of photographs, videos and an instruction manual.
Due to the resins, glues and raw wood, this kit can only be shipped in South Africa. If you are outside South Africa, have a look at the Starter Pack, which can be sent anywhere in the world.
About the Board-in-a-Box kit
The Board-in-a-Box kit includes all the materials and instructions needed to build your own hollow wood surfboard.
Due to the resins, glues and raw wood, the full kit is only available to customers in South Africa. If you are outside South Africa, have a look at the Starter Pack option.
The box includes all the wood (pre-cut and ready for assembly), glue, glassing material, and an online resource page to guide you.
It goes together with an online resource page that includes a 30-page instruction manual with step-by-step instructions, hundreds of photographs showing every step in the process and how-to videos.
Woodworking tools are not supplied.
The kit is suited for people who have DIY or woodworking experience, have a space available at home or in a workshop to build the board and are prepared to work independently.
The advantage of buying one of my kits is that you get a shape that has been built, tried and tested. You get access to the technique to build strong, functional and beautiful surfboards. In addition, you get the best possible materials, glues and resins that you will need.
Have a look at the FAQs section for more information.
– Online instruction manual/resource page – Pre-cut frame and ribs according to the shape ordered – Pre-cut rail strips – Pre-cut deck and bottom planking ready for lamination – Pre-cut nose and tail blocks – Template of board outline – Glue for frame, rail, deck and bottom laminations and glue-ups – Epoxy resin and hardener – Sanding disks or paper for the various grits required – Masking tape – Surgical gloves – Fibreglass brushes – Resin and catalyst for glassing – Sanding resin – Fiberglass cloth – Mineral turpentine/Acetone – Mixing jug – Resin mixer for joint sealing – Leash plug – Wood fin/s to glass on to the surfboard – Masks – Squidgee – Sash clamps (can be rented at some tool hire shops) – F-Clamps, or G-Clamps, 5-10 (the more you have the better) – Orbital sander, preferably 150mm circular but an ordinary rectangular orbital will also work – Electric planer OR block planer for shaping the rails – Router for leash hole although a spade bit on a drill can be used if done carefully. – A flat, even surface to work on – 8-10 pieces of scrap wood, 26mm thick, around 60cm wide.What comes with the kit, and what doesn't come with the kit?
SUPPLIED WITH THE FULL KIT
NOT SUPPLIED WITH THE FULL KIT
All prices exclude shipping. Email Patrick on burnett.patrick@gmail.com to order. 5'.6" fish: R7,800 6' fish: R8,000 5'.8" egg: R7,800 6'.4" egg: R8,200 5'.8" minisims: R7,800 6'.4" shortboard: R8,200 6'.4" single fin: R8,200 6'.8" single fin: R8,500 7'.6" minimal: R9,000 9'.6" gun: R11,500 11' gun: R11,500 9' longboard: R11,000 9'.6" longboard: R11,500 9'.8" longboard: R11,950 11" longboard: R12,850Price List
Who is this meant for? The kit is suited for people who have DIY or woodworking experience, or for people who feel an urge to work with their hands and gain experience in a DIY project. How much time does it take? Building a wooden surfboard is a time investment. To give an idea of the time commitment required, when running a workshop, we start on the Monday and finish on the Friday. This allows for the woodworking on the surfboard to be finished. Kit builders have to budget for this time (five days of work), but they also have to budget additional time for the glassing of the surfboard they build. Is the surfboard guaranteed? As this is a DIY project, Burnett Wood Surfboards accepts no liability for extra costs incurred or injury resulting from construction of this surfboard or of its use. Burnett Wood Surfboards accepts no responsibility for the quality or performance of the final product. When working with power tools, wood, glue, resin, solvents or any other hazardous material, care should be taken to wear the correct protective equipment. Dust, fumes and noise can carry health consequences. The appropriate masks, gloves, eye protection and ear mufflers should be worn at all times. Burnett Wood Surfboards/Patrick Burnett accepts no liability for any adverse consequences resulting from construction of the surfboard in this kit or for the subsequent use of the surfboard constructed. Are the shorter boards easier than the longer boards? The way in which the boards are made is the same no matter the length. What is different is that the longer boards require more work. How comprehensive are the instructions? I have been as comprehensive as possible and am adding more information as people make suggestions. That said, this is a multi-stage process and you will need to be able to work independently and figure things out. How does support work if I get stuck? I am available to answer questions by email or phone, during office hours. How likely am I to make a board that I am proud of? In the workshops that I run, the outcome is guaranteed. Unfortunately because you are working at home I cannot offer the same guarantee. You need to see it like any other DIY project – you are responsible for the outcome. What about glassing? All of the glassing materials are supplied in the full kit and there are instructions for you to follow in finishing this stage. How strong/durable will my surfboard be? Wooden surfboards are very strong. They don’t pressure ding and it needs a strong knock to damage the core structure. However, they are not immune to wear and tear and need to be looked after, just like any other item that goes in the sea.FAQs
The Board-in-a-Box Starter Pack gets you two of the most important parts of a hollow wooden surfboard - the internal frame and shape template.
This kit ships anywhere in the world.
The real value is that with purchase of this kit, you get free access to the online resource page that contains hundreds of photographs, videos and an instruction manual on how to build a hollow wooden surfboard.
The value of buying a frame and template is that it gives you an authentic surfboard shape to work from and access to the online resource that will tell you what else you need and how to put it all together. The resource page includes a detailed 35-page instruction manual that will take you through every stage of building your board. There are hundreds of photographs, and several short videos showing important steps. About the Starter Pack
Here’s what you get: Here's what else you will need: When ordering the frame and template Starter Pack, you will need to allow for sourcing the materials below yourself. Full details are provided in the instruction manual. In addition you will need access to the following tools:What's included and what else will I need?
Starter Pack prices: Boards up to 6'.4″: $230, including free international shipping (7-10 days shipping time) and access to the resource page showing you how to build a wooden surfboard. Boards 7′.6″: $260, including free international shipping (7-10 days shipping time) and access to the resource page showing you how to build a wooden surfboard. Boards: 9′ and above: $290, including free international shipping (7-10 days shipping time) and access to the resource page showing you how to build a wooden surfboard. Hand shaped wooden fins, wooden leash plugs and air vent plugs can be added to the package at your request. Hand shaped fins: $30 per set or single fin Wooden leash plug: $10 Air vent plug: $10 Payment can be made via Paypal or direct bank transfer. Please email me on burnett.patrick@gmail.com for an invoice.
The value of buying a frame and template is that it gives you an authentic surfboard shape to work from and access to the online resource that will tell you what else you need and how to put it all together. The resource page includes a detailed 35-page instruction manual that will take you through every stage of building your board. There are hundreds of photographs, and several short videos showing important steps. About the Starter Pack
Buying a board-in-a-box full kit or a frame and template Starter kit will give you access to this password protected resource page that is intended to guide you through the building of your surfboard.
