Rusty Surfboards – Tech Talk

Tech Talk

We use only the finest materials and most experienced craftsmen to ensure a surfboard with a test-proven design that is light and strong. Rusty and our experienced staff will never compromise on any aspect of surfboard design or manufacturing. Our focus on superior quality and excellent customer service ensures our customers that purchasing a Rusty Surfboard is a great value.

Close tolerance blanks:

Rusty helped Clark Foam develop a series of blanks that have become a standard in our industry. Polyurethane foam blanks are hardest on the outside. As a shaper, or machine, cuts deeper into the blank, the foam becomes weaker. These close tolerance blanks are designed so that minimal foam is removed from the deck of the finished product this leaves a stronger surface and helps eliminate compression damage on the decks of our boards.

Warp glass:

This fiberglass cloth was designed specifically for surfboard manufacturing a few years ago and has become a standard component for the construction of our boards. The cloth is designed so there are more strands of fiber running parallel to the stringers where you need the strength to prevent breakage. The fibers are also flatter than the standard e-glass used by most of the industry so it absorbs less resin and has a stronger bond. It is a little more expensive but it allows us to build a surfboard that is much stronger and lighter than just a few years ago!

“S” cloth:

An option that we offer our customers is “S” cloth. This fiberglass cloth features fibers that are 20% stronger than the standard cloths. It also gives the finished board a whiter appearance. It has a tighter, flatter weave with greater tensile strength than the other fiberglass used in surfboard manufacturing. The flatter weave requires less resin in the lamination process and is much more affects resistance.

A little extra investment in your equipment will give you a surfboard that is stronger, lighter, and have a higher resale value when it is time to get another board. Double Stringers Stringers are made from a variety of wood types. Balsa, Redwood, Cedar, and Spruce, to name a few. For most of our boards we use Spruce because, ounce for ounce, it is the strongest. It is also the most expensive. We take it one-step further.

Two pieces of wood that are laminated together are much stronger that a single piece of equal thickness. Why? All wood has grain and flaws. By putting two separate pieces together, natural shear points are eliminated. In addition, the rocker of the shaped blank is more stable. Why don‚t all surfboard makers do this? Well, it costs even more money. To us, it‚s worth it to insure the durability of your investment.


One of the most notable changes in the surfboard industry in the last few years has been the overwhelming public acceptance of removable fins. This is largely due to the efforts of FCS. Their fin system has proven its viability and versatility. With removable fins, there are the obvious benefits for the traveling surfer. The most important aspect however, is the ability to fine-tune your surfboard. FCS offers an ever-increasing array of fins with different templates, foils, and flexes patterns. We do our best to match each board with the right set of fins. You can, however, radically affect the performance of your board by changing your fins. You can also extend the range of your board by using different fins. Because of their commitment to product development, worldwide availability, and customer service, we have chosen to use FCS exclusively.

Computer Shaping:

The effectiveness and importance of computer shaping cannot be overlooked. For accurate replication of proven designs, we rely on computer shaping. We use several independent “cutting services” to ensure not only quality replication, but also timely service. We provide prototypes that have been test ridden and given two thumbs up by our team riders. When it is necessary to build a large number of similar boards, the computer-shaping machine is an invaluable tool.

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Filed under: Surf Board Design

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