How to Build Your First Surfboard
by Stephen Pirsch

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POLYESTER, OR EPOXY RESIN AMOUNTS-(9' BOARD) PLUS  POLYESTER CATALYST RATIOS

Catalyst, and wax amounts are for polyester only - reduce catalyst (polyester only) amounts if temperature is above 80 degrees F, and do a test batch first.  Do not start an epoxy lamination at over 80 degrees F., unless using a slow hardener.  Cloth amounts are: 1-8oz oz top & bot. w/1-8oz deck patch.

Laminate coat
Bot.- 40oz=12cc cat
Top- 54 oz=16cc cat

Hot coat
Bot.- 18oz=5cc cat & 11cc wax
Top- 20oz=6cc cat &12cc wax

Gloss coat
Bot.- 18oz = 5cc cat. & 11cc wax
Top- 20oz = 6cc cat. & 12cc wax

Fin box
3 oz = 1cc cat. & 2cc wax

Catalyst percentages    .5% .75% 1% 1.5% 2%
Pint=16oz resin  add     3cc  4cc  5cc 7cc    9cc  catalyst
Quart=32oz resin  add  5cc  7cc  9cc 14cc  18cc catalyst

Helpful Equivalents
1cc=15drops
1oz=30cc
1cup=8oz
1pint=16oz
1quart=32oz
1gallon=128oz

Helpful Notes
10cc styrene wax (about 2%) for each pint of laminating resin (to make it dry non-tacky-hot coat and gloss coat only).  Maximum 1oz polyester type pigment/1quart resin (will inhibit hardening of polyester resin at 1oz/1pint).  Note:  Some epoxy based pigments will work in epoxy at a !0% ratio.

How To Figure Catalyst Amounts When You Have An Odd Resin Amount. 

  1. Choose the % of catalyst.  Note:  1% is a good starting place.
  2. Convert the resin amount from oz. to cc. by multiplying oz. times 30.  Example:  20oz. x 30 = 600cc. 
  3. Multiply the resin amount in cc's times 1% .  Example:  600cc x 1% (.01) =  6cc catalyst.

How To Figure Epoxy/Hardener Amounts At A 2/1 Ratio.

  1. Choose an amount divisible by 3.  Example:  You need 44oz. total resin.  44 + 1 = 45. 
  2. Divide by 3.  45 divided by 3 = 15.  15 is the hardener amount. 
  3. Multiply the hardener amount by 2.  15 x 2 = 30.  30 is the epoxy resin amount. 
  4. Add/mix the hardener and epoxy together for the total needed resin.  30 + 15 = 45.

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© 2003 by Stephen Pirsch, All Rights Reserved.

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