When Mike Sheldrake had to retire his 8'6" Robert August Board after 13 years, instead of buying a new one, he set out to see what he could do himself. Though "foams have been structurally adequate and affordable for surfboards", incorporating "cheap and preferably natural materials" was a central part of his initial objective. By developing a structural approach that he calls "the quarter isogrid", ribs can be cut from sheet stock, allowing many alternative and composite materials to be used. Once the board is assembled, the final touch is to glass it with a pre-soaked fiberglass sheet.

Check out the wonderfully thorough description of his process here, and don't forget to check out his site for the boards.

A few more pics after the jump...