SkunkWorks Surf Co.Process - SkunkWorks Surf Co. | Soft Surfboards and Stand Up Paddleboards


Welcome to the Workshop

A lot goes into every SkunkWorks board, it is a process we take pride in. It is our attention to detail which makes sure you are getting the best board possible! To get to where we are now took a lot of research and development, we even had to design custom machinery to suit our needs and yours.

A finished, surf ready SkunkWorks board has a 6mm deck that feels as comfortable as a yoga mat for a rub/rash free surfing experience. It has an unbreakable core, a slick that will take all the punishment you can give it and more. We heat bond our foams instead of using glues so delamination of the slick and deck are a thing of the past. The 20mm/0.787″ thick rails take all the abuse from dragging and storage. Finally we heat stamp our logo into the deck of each product to add grip so you never need to use wax.

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We start by sourcing the best possible materials we can. All of our foams are locally sourced and are eco-friendly.

Core: We only use locally produced PE foam made with a minimum of 30% recycled material. PE Foam is more eco-friendly than polystyrene as well as being stronger and more flexible, however if compressed the structures will always return to their original shape.  Whereas boards built from polystyrene, well once they’re compressed they will never return to their original shape, causing irreversible damage.

​Deck and Rail Foam: This is where the big difference comes into play. Our rail and deck foams are made locally using a completely different manufacturing process than other foams. This production method makes our foams much stronger than our competitors when stretched to breaking point and they won’t let in a drop of water. They can withstand temperature differences ranging from the hottest desert on earth to the coldest regions of the Poles. This means you can leave your soft surfboard or SUP out in direct sunlight on the hottest day of the year or in the snow in the middle of winter and it won’t bubble or crack. They have 10 times less chemical residue after production than our competitors because they are made in the most eco-friendly way possible. No chemicals or solvents are used to blow our foam.Ricky

Slick Bottom: Our competitors use a range of plastics for the bottom of their products, including HDPE just like us. The difference is, our competitors use a PE which has a maximum thickness of 0.6mm/0.024″ while we use a 2mm/0.079″ thickness as standard. This makes our slick up to 3 times tougher than our competitors which is obviously because the slick gets dragged over rough terrains and endures a harsh life of heavy impacts, especially in surf and SUP schools. However with our added thickness, the slick will take this punishment with ease and it won’t snap or crease during its lifespan, whereas our competitors will. Our unique heat bonding method which integrates our slick to the core and rails without the use of any glues also means that standard delamination won’t occur.


Processed with VSCOcam with p5 presetOnce we’ve sourced all our materials we begin to assemble our boards. We don’t use any glues in our manufacturing. Glues naturally break down and become ineffective over time, a process which is sped up by the tough lives soft surfboards and SUPs lead. They constantly go from warm sunshine to cold seas, these temperature changes and the salt water attack and weaken the bond so it doesn’t take long for the glues to break down all together. Once weakened it doesn’t take much until you’re left with a product that is falling to pieces.

Instead we heat bond all our foams entirely. Our heat bonding technology, materials and patented design creates soft surfboard and SUPs that are free of any of the structural weaknesses found in the market today. Once heat bonded, the different sections of our boards integrate together (each part is connected to at least two other parts) and become one single, solid unit.


Each of our boards is carefully designed to give the best experience we can for both the beginner and the experienced surfer. Collaborating with talented shapers we’ve developed the best overall shapes for our boards from rocker to rails.

If you’ve any questions about our process, please feel free to contact us.