15 Steps to Start
Step 1: Find the boards. This can be the hardest part of the whole process, but luckily I have some top blokes in NZ who are happy to see boards going to use and not the tip.
Step 2: Strip the grip tape. Many layers of skin and a few nails have been lost along the way over the past few years. I don’t hate many things in this life, but I most certainly fucking hate grip tape.
Step 3: Strip the glue: Sometimes the removed tape leaves a bare trace, other times it leaves A LOT and unless you want your sanding discs to do a ¼ area of a board you gotta strip that sh*t with either a blade, a scraper or a rag with turps. Great fun!
Step 4: Remove the nose/tail. Easiest with the use of a decent drop saw … but dealers choice.
Step 5: Sand back both sides of the board to remove all remaining glue and graphics. If you leave the graphics on and glue up – yo sh*ts not going to last very long.
Step 6: Decide what you’re making and whether you need a certain pattern. Horizontal cuts get horizontal lines (short), vertical cuts get vertical lines (long). All depends on what you’ll be making for what you do here.
Step 7: Cut. Best to have the use of a decent drop saw for horizontal cuts (and set up a ‘stopper’ so they’ll all be the exact same size), or a table saw for vertical cuts (remember to take off about 5mm of the rounded edge – this is called ‘the unwanted edge’).
Step 8: Lay out your strips and see how well they fit together. Different parts of the deck are shaped differently and as such will fit together differently. Also, if you’ve cut up five different sized boards you’ll have all different shapes/sizes going on … so this dry fit stage is pretty darn important.
Step 9: Once you’ve your layout/colour pattern chosen get your glue-up surface ready and lay out you boards ready for some gluing.
Step 10: Glue all boards (one side) except for the starting strip (left for me as I’m a right hander) and once happy with their positioning – clamp the living sh*t out of them. It’s important to ensure no air pockets cause that’ll mean gaps once dry … so lots of tightening required hereJ F.Y.I – you can never have enough clamps – don’t expect to get a good glue up with two clamps – shit doesn’t happen like that.
*Note: I made some ‘cauls’ for glue up – it’s just a strong flat base with some box iron and receiver rods. Once the woods in for gluing you can tighten down to ensure no movement and that all pieces stay at the same height.
Step 11: Leave 24 hours to fully dry/cure.
Step 12: Remove all clamps and take the fully glued piece from the caul.
Step 13: Clean off your clamps/caul.
Step 14. Trim off the uneven edge and prep your block for cutting into whatever size is required. (e.g. 7-100mm thickness for knife scales, depending on type/size of knife).
Step 15: You’re now at the stage where you can use your recycled block to make whatever it is that you’re wanting to create.
If you do want to have a go & you've any specific questions - flick me an e-mail (email@example.com) or DM me through Insta or Facebook & I'll try and help as best I can!