Obviously my board is a little bit different from ordinary surfboards because of the cavities for the electrics, but you could build any other surfboard the same way.



I decided to design everything in CAD, but you could also just grab a piece of foam and start cutting away everything you don´t need with a hot wire cutter.



Doing it in CAD has a lot of advantages though. You get a really good idea how all the features are coming together, you get perfect semetry if you use a CNC and you can take measurements to double check the model in the real world. CAD is also great to communicate your idea with others.



My surfboard is 150x50x14 cm big. This is the maximum size I could fit on my CNC. So this is about the size of a wakeboard.



The ESC that runs the motor gets very hot, so It will be submerged in a water bath in the small cavity. The big cavity is for the batteries in a waterproof camera box. That box does not need to be submerged, so I added 2 big drainage holes. The plan is that this cavity will drain as soon as I start lifting out of the water. (If I learn how to ride it at all).



Routing the cables is also easier to visualise with CAD. You can see on the third picture how the cables will be routed from the ESC to the mast.



The blank has to be cut in two layers of 40mm foam and one layer of 60mm foam in the middle.

