A Comprehensive Guide.

HOLLOW WOOD SURFBOARDS

Build Hollow Wood Surfboards with AkuShaper

Download files from Akushaper to get started.

There’s nothing quite like riding a surfboard you’ve built yourself — especially when it’s crafted from sustainably sourced wood. Hollow wooden surfboards combine timeless craftsmanship with modern design tools, giving you a hands-on, environmentally conscious way to connect with surfing from start to finish.

Whether you’re a backyard builder or an experienced shaper, AkuShaper makes it easier to bring your vision to life. You can precisely design internal structures, outline curves, rocker profiles, and volume distribution — all while planning your build around the unique behavior of timber.

But not all wood is created equal. Different species of timber vary in strength, weight, cost, availability, and how they react to moisture and bending. Before you start your build, it’s important to research your timber options. Consider factors like:

  • Density and buoyancy

  • Grain consistency

  • Resistance to saltwater

  • Regional availability and price

  • How the wood will handle shaping, gluing, or bending into curves

From red cedar and paulownia to recycled planks and locally harvested lumber, your choice of wood will shape both the look and the performance of your board.

On this page, we’ll explore how AkuShaper supports every step of the hollow wood board-building process — from planning internal chambers and outlines to printing custom templates and adjusting for material thickness. Whether you're designing a traditional fish, a classic single fin, or a modern mid-length, this is your complete guide to combining precision software with natural materials.

Three Main Design Pathways in AkuShaper

No matter your tools or experience level, AkuShaper gives you flexible options to bring your hollow wooden surfboard to life. Whether you’re cutting by hand in your garage or exporting files to a CNC machine, you can start with a precise digital design and move seamlessly into physical construction.

Here are the three main ways to use AkuShaper for hollow wood surfboard building:

1. Print Full-Size Templates for Hand Cutting

Perfect for traditionalists and DIY builders, AkuShaper lets you print full-scale templates directly from your digital design. These include:

  • The board’s outline

  • Rocker profile (side view)

  • Cross-sections or slices of the board

You can glue these paper templates to your timber stock or plywood sheets and cut everything by hand using a jigsaw or bandsaw. It’s an accessible, low-cost method with high precision — great for first-time builders or anyone who enjoys hands-on craftsmanship.

NEED TO ADD HAND CUTTING PHOTOS, BAND SAW, JIG SAW, ETC.

2. Export DXF, IGES, or STL Files for CNC Cutting

If you have access to a CNC router or laser cutter, AkuShaper allows you to export your board’s outline, rocker, and internal slices in industry-standard formats like DXF, IGES, or STL. This makes it easy to:

  • Cut accurate ribs and stringers

  • Nest parts efficiently on your material sheets

  • Scale up production or experiment with multiple prototypes

It’s ideal for schools, workshops, or experienced builders who want the repeatability and speed of CNC tools — while still working with beautiful natural wood.

3. Use HBTM (Hollow Board Template Maker) with Aku Files

For those building frame-style hollow boards, the Hollow Board Template Maker (HBTM) plugin works seamlessly with AkuShaper files. With just a few clicks, you can convert your Aku file into a detailed internal skeleton layout — including:

  • Precise frame ribs

  • A center stringer

  • Slot and tab joints for assembly

This approach offers the best of both worlds: modern digital design and efficient template generation, with a finished board that’s light, strong, and stunning.

Please visit this page to download the Hollow Board Template Maker: https://help.akushaper.com/category/18-hollow-wood-surfboards

Construction Types

Hollow Wood Construction

Timber ribs and centre spine, outer rail strips, either narrow strips, flat rocker shaped pieces or our Stacked Rail Method with timber skins. Perfect for the DIY Builder, with little to no experience. Requires a vent.

Read more here:

Bow Frame Construction


Sturdy timber outer frame with ribs giving support through the centre. Timber skins. Not as popular as the other methods, requires a rocker shaping table and shaping knowledge. Requires a vent. Can be made by the advanced DIY builder.

Chambered Construction


Sections of timber cut to the rocker shape, tack glued then roughly shaped. Separated hollowed out glued back together. Then final shaping. Requires a vent. DIY builders do make them, there's lots of waste timber and some shaping knowledge is required.

Foam Core Construction


Shaped foam core with timber rails and timber skins. This one is the easiest and quick method to build, does require knowledge of shaping, doesn't require a vent and won't flood with water if badly dinged.