The SEABASE E-Series Technology explained.
Seabase Epoxy Surfboards are leading the world in new technology for custom made surfboards. Based on the new EPS (Expanded or extruded Polystyrene) technology blanks from US Blanks in America, Seabase use the new Superfused (extra-fused cells to enhance the waterproof quality of the foam) EPS foam moulded into blanks from plugs by some of the worlds best shapers, including Eric Arakawa and Timmy Patterson. For years blanks have been made from Expanded Polyurethane Foam (PU) a technology honed by Clark Foam.
Recent advances in Epoxy resin by USA Company Resin Research has meant a huge advance in the characteristics of Epoxy Resin – it is safer, stronger and easier to use than ever before. Look for the e-series label on all our Epoxy boards. Its a sure sign of quality and performance with Epoxy.
We need to explain why our E-series and Seaflex (Parabolic) boards from the Seabase factory are generally more expensive than other company’s boards. It also helps understand why we are so successful in contest arenas. This process, a new way of making surfboards, is so open to shortcuts and shoddy manufacturing.
We begin by hand shaping the EPS blanks, either conventional single mid-stringered, or the new parabolic blanks form US Blanks. We have a machine, and we use it, but it’s still noticeable that the end product we get from machines is not always consistent. It should be, but pilot error and other variables (blank density, stringer thickness, flex, twist, setup, blank quality etc) often means the machine shape is nothing like it should be. In the meantime, our in-house shapers Mark Neville, Luke Hart and Matt Barrow still produce contest winning boards finished by hand – in the same way as the world top 44 surfers still have their surfboards hand shaped for them.
So we hand select the EPS blank and hand shape them. This is a three hour process for Mark Neville, he is so particular and fussy. Other shapers can shape a board in less than one hour. The raw blanks are then sealed – not always necessary but we do it with a secret blend of materials that not only seals the blank cells but helps with adhesion of the laminate. (Why? Because EPS cells are more open and less tight (meaning lighter foam) than PU cells).
After the blanks have boxes fitted. we hand laminate all boards – using three layers of fibreglass on the decks and two on the bottoms, and the latest Series 2000 and 2020 Resin Research Epoxy. Using three 4oz deck layers is far more expensive than two 6oz deck layers for the same weight of cloth – but the three layers in a laminate are far more effective in a sandwich construction than two layers. Hi modulus unidrectional and bidirectional Carbon Fibre is added if required in a separate process.
The EPS boards are heat treated at temperatures up to 45 deg C for 24 hours. This fully cures the resin, especially where the fins are fitted, and usually throws up any problems we may have later with heat “blowing” air and forcing the lamination of the board.
The boards are sanded and hand finished after lamination then coated with at least three layers of our proprietary board sealer White Flash! (Why? The sanded fibreglass bundles need sealing to prevent them wicking water and causing delaminating).
The boards are Quality Controlled and are packed ready for sale.
Note : The nature of surfing, and the forces involved, are such that while we warranty our surfboards are made to the highest standards from the best materials, no guarantee against damage or breakage is offered of implied.