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Taking it Further

All over the world, thousands of custom decks such as pool boards, drop decks, dancers and downhill boards have been designed and pressed using the Roarockit system by enterprising builders.

With Ted Hunter’s pioneering use of foam to shape the mold, builders can now design and shape their own styles of decks. Tutorials are posted here. here.

Composite materials such as carbon fiber and fiberglass can also be used in the Thin Air Press. Inlay and marquetry have also been used with great success.

Veneer is available in uncut sheets for custom shaping, as well as larger Thin Air Press vacuum bags. Use of a bandsaw or jigsaw will be required to trim out custom shapes.

Points of Learning:

  • explore existing skateboard styles, shapes in relation to their uses
  • construction planning and designing for a new or improved skateboard
  • include these construction properties
    • changing the number of veneer layers
    • including more or less cross band grain or long grain layers
    • strength and flexibility vs shape
    • using different adhesives, ie: wood glue vs epoxy
    • learning to use composite materials, ie: carbon and fiberglass
  • drafting custom templates for a new deck design
  • shaping foam molds using templates, foam sheets and hand tools
  • hands-on experimentation while building custom decks
  • hot wire method to shape a foam mold

Please note that Taking the Process Further as listed on this page requires a high level of experience with both building decks in the Roarockit Thin Air Press and using composite materials. This is not recommended for first time builders, trust us!!


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Build Skateboard Decks in Class!
Curriculums and Lessons
Math, Science and the Physics of Vacuum
Woodworking without Power Tools
Skateboards are Green
Skateboard Art and Design
Business and Entrepreneurship
Teamwork, Leadership and Mentorship
How to do it?
Taking it Further
Materials/Resources

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