Cutting a surfboard outline with a router

Cutting the outline of a surfboard is one of the first steps in the process of shaping. Cutting the outline square and fair is critical to getting fair flowing rails that don't have wobbles in them and are easy to shape.  When I began building boards this was often a step the took a lot of time to get right using a hand saw and surform to clean up.  Over time I switched to using a router to cut these because I had better, consistent results and was able to reduce the amount of time it took to template a board to about 15 minutes start to finish.

The tools I use to do this with are: 

  • Masonite template, key that it be perfect
  • Bushing Guide on router base
  • 2.5 in x 1/2" Freud 2 flute router bit (if you can get a 3" that would probably be better but the 2.5 will do the trick)
  • Porter Cable D handle router with 1/2" collet
  • Spring Clamps, one of which has been modified with longer jaws.