In short: glue rails, a top and bottom deck either side of a wooden frame. In between, add fibers to strengthen the board, so you don't stomp it to pieces. Finally, treat it with a coating that can handle salty seawater.
Sounds easy? Building a wooden board by hand is actually quite a challenge. The process starts with computer-aided design that allows us to play with shape and volume before actual production starts. Our hollow wooden boards come with a core of marine-grade plywood and an outside layer of low-density wood, balsa. We use other woods for decoration and additional strengthening.
Every element of the core frame, decks and rails, including double curved 3D shapes, are cut, bent and shaped by hand, assembled piece by piece and glued into a blank form, before actual board shaping, glassing and plug placement takes place. The result of this hard work, which takes about 6 weeks, is a beautiful, durable and more sustainable board.
The image below gives a detailed overview of the layers inside a typical hollow wooden board with glass and epoxy coating.
Air vents are made of seawaterproof material and are needed to control the air pressure in the board. Moving in and out of the water, stark temperature differences influence the air pressure in the hollow board, and may cause rupture. Removing the vent plug when out of the water will help protect your board against over- and under-pressure.
You should note our wooden shortboards are up to 20% heavier than its foam equivalent, while longboards are up to 10% lighter.