A step by step guide on how to build your own balance board using materials from your local hardware store. By Kathy Westergaard, Encinitas, California. (Mar 2003). Unfortunately this isn't republished with permission, I've been trying for ages to get hold of Kathy to ask her but have had no luck. Send me a mail if you ever see this Kathy 'cause I think it's great.

Supplies

I bought all the supplies for the project at Home Depot. If possible, get a friend to make one too and split the costs because some of the supplies are sold in quantities far greater than needed for one balance board. The measurements given below are to build a board similar to the Indo brand "original" model balance board—you can make the board any size and shape you want.

Necessary supplies:
* Plywood sheet: 1/2" or 5/8" thick. Approx 20" X 30" for the board plus 2 2" X 20" strips for the bumpers
* Pipe: 4-6" diameter, approx. 18" length
* Friction tape: 2" wide, 4-6'
* Wood glue

Optional supplies:
* Wood stain or paint
* Polyurethane
* Non-skid additive
* 2 Pipe end covers
* Sand

Suggested tools:
* Measuring tape
* Newspaper, pencil, tape, scissors
* Saber saw/Jigsaw or router
* Sander or sandpaper
* Hacksaw
* Clamps
* Carpenter square
* Paint brush
* Razor blade

Making the Board

Step 1: Create the balance board pattern
Take a piece of newspaper or butcher paper and cut it to 30" X 20". Fold the paper into quarters. Along the outside edge (not the folded edge) draw a curve then cut along this curve. Unfold the paper and you should have a fairly even oval pattern.

Step 2: Trace and cut the plywood
Tape your paper pattern to the plywood then trace the pattern in pencil on the wood. Using a jigsaw or whatever woodworking tools you have available (we used a router), cut the plywood into the shape of the pattern. If necessary sand the edges of the plywood until smooth.

Step 3: Add bumpers
Cut two strips of plywood, 2" X 20". Using wood glue, glue the strips flush with the two ends of the board and parallel to one another. I used a measuring tape and carpenter square to make it as even as possible. Clamp the two strips down and let dry for several hours or overnight. Once dried, cut the excess wood off so the bumpers match the shape of the board (a router works best for this.) Finally, sand down the edge of the two boards so it's one smooth edge. If you're going to stain the deck you should also lightly sand the deck with fine sandpaper to prepare it.

Step 4: Make the roller.
Using a hacksaw, cut the pipe to 18" length. Attach three strips of friction tape to the pipe—one in the center and one on either side a couple inches in from the ends. I measured the desired location and put down a strip of masking tape as a guide to make sure the friction tape was applied straight. Use a razor blade or sturdy scissors to cut the tape to size.

Optional: If you want to slow down the action of the board you can do so by pouring a few cups of dry sand inside the pipe then putting on the pipe ends to seal it up.

Step 5 (Optional): Add textured finish to the deck
You can either leave the board unfinished or add sealant and texture to the deck. The texture will help you to keep from slipping. You can stain or paint the deck before you seal it. I stained mine blue.

Pour some polyurethane into a jar or plastic cup and mix in a small amount of the non-skid additive. Brush the mixture evenly over the deck of the balance board. Allow to dry for several hours (follow directions on can.)

I first saw this article published on www.irishsurfer.com.