Skateboard decks may seem simple to manufacture, requiring just a supply of wood and some tools for shaping. However, the actual process of making a skateboard deck can be quite complicated, and decks go through a number of stages of production before they are finally ready to be skated on.
Treating The Wood
Although some skate decks are made from metals and plastics, wood remains the most popular and widely used material in deck manufacture, with maple being the common choice. Splitting down the maple is the first step in deck manufacture. The wood is specially treated so that each layer, or veneer, can be peeled away from the others. These are then delivered to the deck maker and stored in climate controlled areas to keep them supple and in perfect condition.
Initial Glueing
Each veneer is taken and hand placed into a gluing machine. This machine coats each individual veneer in a water-based glue, laminating each section to increase its strength. Veneers are then separated into sections depending on the grain pattern on each, and this determines where they will be used in the manufacturing of the actual deck.
Beginnings
Each skateboard is made up of seven separate veneers, each with a typical thickness of just 1/17 inch. The top and bottom two layers use veneers with grain running the length of the deck, while the middle three layers incorporate opposite grain directions to aid the strength properties of the deck. The layers are placed into a mold, which presses the decks, creating their nose, tail and concave patterns.
Timing
The newly formed decks are then held in the press for a period of between one and one and a half hours, depending on the individual policy of the manufacturer. This helps to bond the veneers together tightly, increasing the strength of the deck. The general rule is that the longer the deck is kept in the press, the more strength it will have.
Drilling and Shaping
Once removed from the press, the deck can really begin to take on the shape and form of a traditional skateboard. The first step is to drill holes for the hardware to be attached. This is done with a number of decks at the same time, and accuracy is therefore crucial. Next, the deck is shaped. First, it is flush-cut into the square outline of a board before being corner-cut to create the final rounded edges of the deck.
Finishing
Finally, the deck is aesthetically improved. This involves sanding the deck down on the edges and base to smooth it out. The deck is then either colored and varnished to be sold as a blank, or screen printed with individual designs for sale as a graphic deck.
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