Vernor Surfboards custom wakesurf

So...after 2, maybe 3 years on a Walker Project Bullet...the foundation for which was a design that James and I came up with in the garage, we decided to make a change of manufacturers.

We've been out with Jerry Price of Shred Stixx and Chase Hazen and watched what Vernor's been shaping. Also Dave took Jerry's design for the Shred Stixx Noserider and made that 8'6" for us.

I called Jerry last week and he used his mojo to get us a board from Dave before the World's.

The new board will be EPS and Epoxy. I've mentioned on several occassions that boards made from epoxy (Inland Surfer, Shred Stixx, etc) are faster. In a different thread Jerry comments that Epoxy is stiffer and that translates into faster boards.

Dave shaped the board while I watched and was kind enough to let me take a few pictures during the process.

The shaping bays are all upstairs and there are numerous blanks in PloyU and EPS ready for shaping.

One of the shaping bays, notice the blue walls and blank level height lights that allow the shaper to see any irregularities (via shadows). In the background you'll see some of the tools of the trade - Dave has two planes that he uses. Working with EPS requires slightly different use of tools.

This is a picture of the downstairs where sealing, glassing and some polishing takes place. Note the rack of boards curing on the wall.

Tools of the master. Two planers, a sander and instead of a handsaw, a jigsaw to quickly take down the outline.

More tools...on the wall you'll see templates that are used to draw various shapes onto blanks. Every shaper has their own designs that are reused stored in these templates.

I was interested of read all of the notes and pictures on the walls (not the ones to the right in the picture - I looked, but only for a second!) Dave has been shaping boards for over 20 years and he has a rich history of thanks and congratulations in the various news clippings and photos that line the walls of his shop.

Vernor uses a very specific EPS blank. He was telling me that there are some fairly substantial differences in quality and density. The source of his blanks are 2 pound density and Dave and his staff have actually verified it. Quality in manufacture and materials is paramount with Vernor Surfboards. Two pictures of the blank getting ready for the first cut. These blanks come in rectangle, but with the rocker hotwired in.

First cut.

Outline done and starting on removing the excess thickness with a plane.

Huh, I didn't notice those posters on the wall before. Did you guys notice that?

After all the shaping the board ready for sealing, fin boxes and epoxy. The shaped blank was "maybe" a pound to a pound and a half. I'm estimating the final glassed board will be in the 3.5 to 4.0 pound range. As Jerry was pointing out that's a 20% reduction in weight, or like a surfer dropping 10 pounds. Amazinglingly light.

Vernor Surfboards website

http://www.vernorsurfboards.com/

Ridiculously fantastic.

Isn't that weight reduction incredible? This board will carry the Shred Stixx logo. Jerry has discovered the advantages of epoxy which translate into strength and lighter weight, without affecting the flex characteristics. You can't just transfer a "magic" ployu board to EPS, there are some differences, but with the skills these guys have learned, they are able to manufacture a board that is lighter, stronger and flexes like a polyu board.

Jerry's boards now are available in Epoxy construction:

http://www.shredstixx.com/boards.htm

It was when I watching Chase on the Chase Hazen Pro model that I was so impressed with the innovation coming from the R&D team of Jerry and Dave.

Good Stuff...Be sure and post the final product.

David, Quit looking at yourself on the computer and get back to work! HA

Thanx Jeff for nice pics. I'm on a start of shaping my first board (EPS or Styro).

btw. I sent you PM Jeff.

Hey Hawaj, sorry, I just responded to your email.

that board looks sick.

I think he uses the posters as a kind of tool, French curve if you will. They probably come in handy when your working on a new board that needs a new shape.

That's cool to see...thanks for sharing those. I love seeing how these boards are in the process of being made.

PS: Nice posters hehehehehe

yea the posters keep you motivated when your tired of shaping boards

Just picked up the board from Vernor and planted it on the postal scale here at the office. Without fins or traction, and with 3 layers of 6 oz glass it is 4 pounds 2 oz. We are heading out to give it a test, hopefully I'll get some pictures this evening.

Can't wait to hear the results! Congrats on the new stick!

Two quick pictures, it's past my bedtime!

Jeff, pictures are great... However, what is James' 411 on the board???? How is the new board compared to the old board? More responsive/Less Responsive??? Was the new board made exactly like the old or did Vernor's help out with slight modifications that would help James out?

Too early to tell. Preliminarily, the EPS is substantially more bouyant than an equivalently sized polyu core. Dave made the thickness of this board about 1/16" less than what we had, before.

The issue with "too bouyant" or maybe more appropriately "more bouyant" is that it affects the way the rails work. Honestly, I think that you can take an outline from PolyU and probably cut 5% of the size/volume off of it. So a 4'5" board becomes a 4'2". Same with the width/thickness, etc.

James loves his old board, and Dave put his own interpretaion in to this design. This version is exceptionally responsive rail-to-rail. James had a little trouble adjusting to it in the hour or so that we got to ride.

A few more miles under his feet and we should be able to get a better feel for it.

The EPS/Epoxy construction is very interesting and offers some huge advantages in design and actual ride. It'll be fun to see where this leads.

thanx Jeff, and how is rail? Sharp all the way?