Shaping Room

Yellowfoot wooden surfboards are handcrafted in the black forest -

from the first cut of the timber to a perfectly finished surfboard. Once the design of the surfboard shape is perfectly developed, the selection of the finest and lightest wood stands at the very beginning of each board.

Balsa wood

Balsa wood is by far the lightest wood on the planet. We import the balsa wood from Ecuador, its country of origin, where the balsa trees grow on sustainable and eco friendly farms. As a very fast growing tree, balsa wood in general is not an endangered species. A balsa tree is ready to be harvested after 3-4 years.

The selected balsa wood for our wooden surfboards has a maximum density of 0,12g/cm3. This extra light balsa wood gives the wooden surfboards an incredible stability, longevity and its unique flex. Compared to any foam used in surfboard production, balsa wood does not origin in a harmful and polluting production process.

As a sustainable and fast growing raw material, balsa surfboards are the ecological alternative in surfboard manufacturing. The construction oft the blank starts with the selection oft the dried wooden timber and a new balsa surfboard is born.

construction

"OTT" - One Timber Technology:
Unlike most wooden surfboards, yellowfoot surfboards are not a product of a series of plywood ribs glued together and then sheeted with thick wood strips.
For our balsa surfboards we use the OTT, the one timber technology. Thanks to the OTT, our surfboards exist of a strong and solid full balsa wood core: Thick timber forms the blank, leaving no critical joints. This gives the board the natural flex of the fibres of the tree, resulting in a fast board with better flex properties, giving you a sick ride.

Yellowfoot wooden surfboards are custom made and handcrafted. So it’s up to you to decide whether you go for a chambered or a solid balsa surfboard. The hollow balsa surfboards are lighter and offer similar stability to the solid wooden surfboards; therefore most wooden surfboards are chambered.
High quality manufacture and processing are main company values. The right technique from the first cut of the timber through to pressing the blank for a maximum strength of the connection. Our blanks are glued and pressed with a durable adhesive bond ensuring durable joints for long lasting surfboards.

Blanks

Recycling scraps from the veneer supply: American nutwood, african rosewood or american cedar, perfect for stringers, nose & tail blocks:
Stringer: One, two or none?
Different construction types, the desired flex and your personal taste influence this decision. Thanks to the natural stability of balsa wood and by the use of the OTT, it’s even possible to put no stringer at all!
Nose & Tailblocks: more than an optical feature!
The delicate spots like the nose and the tail of the surfboard are reinforced and protected in case of an accident. The dense types of wood don’t suck water and leave lots of room for creativity! Get inspired!

Shaping

After six years of shaping and crafting balsa surfboards with our hands, we established CNC technology to the production process in 2013. Based on our experiences and recommendations from team and test riders, we are now able to produce and reproduce the best and most popular shapes in increased quantity, supported by CNC technology. Trust us, you’ll still find loads of handcrafting in these boards.

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Lamination

Because of its advantages compared to polyester resin, yellowfoot balsa surfboards are laminated using epoxy resin. Epoxy resin is the healthier alternative to polyester: it’s less destructive to our environment and to our health. It is lighter than polyester but the strength and durability of epoxy in general might be the biggest advantage. We are constantly on the search for a even more environmentally friendly resin with appropriate quality characteristics that comes up to our high expectations.

The triaxial flexglas fabric
We are using a high quality, extra strengthened, stich bonded triaxial fiberglass cloth. Yellowfoot balsa surfboards come glassed with 2x4 oz fiberglass cloth on the deck and 1x4 oz on the bottom (Version 4-4-4). Alternatively you can pick version 6-4, with 6 oz fiberglass cloth on the deck and 1x4 oz on the bottom. Due to the stiffness of the balsa wood in combination with the One-Timber-Technology, this thin coat of fiberglass makes the surfboards strong enough, yet providing the lightest possible result.