How to make a simple mold to build your own Wood SUP paddles

The strongest way I can think of to make a paddle is to use multiple strips of wood and glue them together for strength. Similar to how a skateboard deck is put together. If the skateboard deck was just one layer of wood, it would be way too flexible and weak to support the skaters weight as he or she bashes it from all angles. That is why skate decks usually have 7 layers of various woods all glued and pressed together in a mold.

In this article, I am going to show you step by step exactly how to make a simple and cheap paddle mold. You will need some tools to make this easier. I'll list them below.

Tools you will need:

1. Protractor
2. Pencil
3. Straight edge
4. Speed square
5. Table saw
6. Chop saw / miter saw / or hand saw
7. F Clamps
8. Sanding block (120 grit sand paper)
9. Block plane / Jack plane / or Jointer if available 
10. Tape measure

Materials you will need:

1. (1) 2X4X8' standard stud (Duglas Fir)
2. wood glue (Tite bond 3 is perferable)
3. Masking tape
4. Thin piece of scrap plywood

Step 1: Marking the first cut

Lay your 2X4X8 board flat down on the ground. With your tape measure, measure out 16" from the edge. You can use a speed square to mark a straight line across the board. 

Step 2: Cut and separate the 16" block

Cut along the line you marked with your chop saw / miter saw / or hand saw. 

Step 3: Rotate the 16" block

Rotate the 16" block so that the broad side is facing you. 

Step 3: Marking the angle

Place the center of your protractor on the bottom right hand corner of the block. With a straight edge and a pencil, mark out a line that extends at a 10° angle from the corner. 

Step 4: Cutting the angle

Use your table saw to cut this long piece. WARNING: Do not attempt to free hand this cut on a table saw. You WILL rotate the block in the cut and it WILL shoot back out at you. This could possibly lead to injury or death. Instead use a sacrificial piece of wood to use as a guide. This sacrificial piece of wood will ride against the fence of the table saw. Use masking tape to attach the 16" block to the sacrificial piece of wood at the 10° angle. 

Step 5: Mark the second angle

Use your protractor to mark a second 10° angle from the corner shown above to the edge of the block. 

Step 6: Make the second cut

Use your table saw to cut the second piece of the block in the same exact way you cut the first block. Use a sacrificial piece of wood to ride along the table saw fence. 

Step 7: Align the two pieces next to each other

Create a large double ramp with the two blocks of wood. Try your best to align them together. If the ramps are not exactly aligned at the same 10° angle, you can use a jointer or block plane to bring them flush with each other. Touch it up with your sanding block. 

Step 8: Glue and clamp together

Once your pieces are aligned, you can now glue the bottom of the ramps to the flat side of the stud. Apply a generous amount of wood glue and clamp down with your F clamps. Let it cure for an hour. 

*You might have a gap in between your ramps. This is ok. Make sure your ramps are flush with the edge of the stud so that you have a gap in between the ramps. You can then use a scrap piece of thin plywood to cover the gap. 

Thats it! Your new wood SUP paddle mold is now complete! See the next article on how you can use this mold to make your own paddles! 

-Dennis Jiron