Buzzard Bodyboards technical stuff . . .

Buzzard Technical stuff . . . .

Core

We use Dow 220 (2.2lbs/cu ft) for most boards at nearly full 2 inch thickness when finished. This a LDPE (low density polyethylene) foam which comes in 9 foot planks. We also use Dow 400 (4lbs /cu ft) foam for some custom and Big Bro boards. This core is incredibly stiff and when used at full thickness with an HDPE deck almost impossible to bend and is very hard to ride unless you weigh 16 stone plus! (but see user's views from Marcus.) Supalite boards use the new Zfoam core. Rail-cutting tables, with nose-taper cutter at far end

Figure 1 - Rail-cutting tables, with nose-taper cutter at far end

The core is cut to working length (44 - 48") and cut with templates and bandsaws to shape and rail angle. Then the board is sanded down to final thickness (Figure 3) and the nose taper is cut using a swinging cradle bandsaw.

Base
The Surlyn or HDPE slick, which we use on all boards, is then heat laminated to the bottom of the core foam using a moving laminating table. (No glues or solvents - very hot air only).
Figure 2 - The heat-laminating table

Deck
The deck is either cross-linked LDPE Zeedec, made in England, or HDPE Hiseal (uncross-linked) which comes from the USA. It is then heat laminated to the top of the board. While the board is still hot, the deck is pushed down over the upper rails and laminated to the rails with a hot air gun and glove. After further cooling the board is put back into the templates and the lower rail area is re-cut using a spindle-moulder.
Figure 3 - The Sander-thicknesser and Spindle-moulder

Rails
The lower rails - always HDPE Hiseal - are then fitted by hand using hot air gun and gloves and trimmed to size, a second rail is then fitted if required. For the Winger Control System a third rail is fitted and before smoothing a small (half-inch high) wing fin is shaped 3-6" long 3" from the tail.
Figure 4 - Dave smoothing the rails

Nose and Tail
The nose and tail are then cut to shape - crescent, bat-tail, or whatever you want - and then the HDPE Hiseal is fitted using the heat gun as before.
Figure 5 - Dave fitting nose and tail (to a BodyGun)

Finally
All the rails, nose and tail are trimmed with a special knife giving an eighth inch stand-up. This is then heated until partially molten and then finished to give the board a strong waterproof surface.

Now . . .
Fit a leash and try it out!!

Technical enquiries to Dave at: dave@bodygun.co.uk

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Core
We use Dow 220 (2.2lbs/cu ft) for most boards at nearly full 2 inch thickness when finished. This a LDPE (low density polyethylene) foam which comes in 9 foot planks. We also use Dow 400 (4lbs /cu ft) foam for some custom and Big Bro boards. This core is incredibly stiff and when used at full thickness with an HDPE deck almost impossible to bend and is very hard to ride unless you weigh 16 stone plus! (but see user's views from Marcus.) Supalite boards use the new Zfoam core.
Figure 1 - Rail-cutting tables, with nose-taper cutter at far end
The core is cut to working length (44 - 48") and cut with templates and bandsaws to shape and rail angle. Then the board is sanded down to final thickness (Figure 3) and the nose taper is cut using a swinging cradle bandsaw.