Cutting and gluing the hollow structure

The hollow structure is nothing new. It was introduced by Tom Blake in 1927. It's old stuff but it works very well.

This step requires a jigsaw, loads of glue (chemical Polyurethane glue) and many many clamps.

 Shaping and adding the plugs

Let's take the hand plane and sanding pads to shape the rails, nose and tail(my favorite part).  This is all about Searching perfect curves  and working slowly to achieve a perfect shape and symmetry.

Then we make holes to fit in all the plugs :fins, leash and air valve (the air within the board can expand causing damage so you'll have to close the airvalve whane going in the water and open it when the board is on dryland. 

All the plugs are sealed in using epoxy resin. 

Decoration and final touch.

Here you can ask for almost anything you want (design and artwork on demand) pencil, ink or watercolor.
Eventually the board can be either varnished (Polyurethane  varnish) or oiled with special hard oil (mix of different natural oils to protect the wood).  

I don't propose glassing the boards as it is (in my opinion) unnecessary additionnal weight   and more importantly, resin and fiberglass are the worst elements of a conventional board regarding the environnement.