Making a Paipo Board

Part 2
Just like the cooking shows demonstrate how to do something and then miraculously pull a finished one out from nowhere, I had already had a blank, with a reinforced nose, ready to go for Cory so that he could make a blank and then sand one and begin finishing it, all in the same day. But for an actual weekend project this would start day 2.

After the glue dries, Cory cut out the general shape.

Now comes the fun part, sanding. We started with a genuinely barbaric grinding sander with #50 paper, which if you're not careful can remove huge chucks unintentionally, or worse, almost cut your board in half. But it's one fast way to even out and continue shaping the board. (Hand rasps and planers work better, but that's not quite as exciting for a young boy.) This is the only area where I actually helped him because the reinforced nose takes a little work.

After the grinding sander comes a hand rotor sander which can bring you down to a pretty smooth product. We began with #100 paper, and then did it again with #180, and finally #220.

Cory then spent a decent amount of time hand sanding with #220.

He was very proud at how smooth he got it.

Then the board gets dusted, and 2 coats of a quick dry wood sealer gets laid on.

When the sealer was dry, we put on 2 coats of a quick dry polyurethane but not before Cory put his personal sticker on. (Below)

The board at this point is only a "wall board" and should not go in the water. We sent Cory home with enough Marine Varnish to give it 6 to 10 coats. Problem is you need at least 24 hours between coats. So in about a week to 10 days Cory should be in the water with it.

  Proudly - Handmade by Cory


Cory's first Paipo Board,

that he made himself.

I think he did a great job!


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