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Blackfern Boards x Pendleton, up close

The weather is right for hitting the waves. We’re celebrating summer this year with a Blackfern collaboration; two boards that are part of our Surf Pendleton collection. So here, in their own words, are all the steps that go into making these fine boards–one at a time, all by hand.

This slideshow requires JavaScript.

Making the Pendleton Limited Edition Surfboard

Each Pendleton Limited Edition Surfboard is shaped, painted, glassed, sanded, and glossed by hand in Blackfern’s fabrication studio in Portland, Oregon.

Retro Styling

For the Pendleton Limited Edition Surfboard, a 1960′s era single fin model was chosen.  This timeless retro board embodies the lifestyle of the era; clean, simple, and stylish.  Many of these retro shapes are having a resurgence in popularity because of their versatility in a range of surf conditions.  The board style pays homage to an era in which Pendleton was a vibrant force in Californian surf culture.

The Process Starts

The first step in the fabrication process is to trace out the outline of the board onto a blank, which is a rough-cut piece of foam that resembles a surfboard, albeit not a very functional one.  The outline is cut out of the blank, not unlike making Christmas cookies, and the excess foam is removed.  The outline is then tuned by a rasp-like tool called a surform, in order to hone the perfect curve that will define the finished board.

From Bottom…

The next step is to craft the bottom of the board.  This process begins by power planing or “skinning” the protective outer shell of the blank that protects the softer foam within.  After the skin is removed, the bottom contours are shaped in by removing material with additional passes with the power planer, surform, and finally, sanding blocks.  The single fin model features shallow concavity through the middle of the bottom, blending into a V contoured tail.  These contours give the board a loose and nimble feel with higher performance than would be achievable with a flat bottomed board.

…To Top

At this point it is time to flip the blank over and begin working on the top of the board.  Similar to the bottom, the first step is to remove the protective skin of the blank.  During this process,  I start to flesh out the top contours and the “foil” of the board.  Foil refers to the changing thickness, both from the center towards the rails as well as from the tip to the tail of the board.  It is during this process that a shaper’s ability to visualize in three dimensions becomes crucial.  Knowing where to remove material and in what quantity can be tricky.  The goal is to produce a smoothly foiled board; maintaining volume in helpful areas and removing it where unneeded.

Forming the Rails

After the top has been shaped and foiled, its time to move onto the rails of the surfboard.  At this point the board has a functional top and bottom but with its boxy, vertical rails, it would be miserable to surf.  To form a smooth curving rail, I begin removing rail material in the form of rail “bands.”  Bands are sloped ridges that run the length of the board; thickest at the middle and thinner towards the tip and tail.  By removing rail material incrementally in these stepped ridges, it is possible to produce a rail that changes shape and thickness in a controlled and consistent fashion.  Once the bands are crafted to satisfaction, the board is turned onto its rail and I begin passing a sanding screen over the ridges of the “bands.”  After screening repeatedly, the ridges disappears and a smoothly curving rail emerges.

Finishing Foam Touches

The final steps of the shaping process are to install the slider single fin box and to finish sand the entire shaped surfboard to a buttery smooth finish.  The board is signed off to the customer who ordered it.  I write the customer’s name, the dimensions of the board, and finally “Pendleton Surf Limited Edition.”

Getting that distinctive Pendleton look

The specialized Pendleton artwork is applied before glassing the board.  The two color versions vary on their preparation.  To produce the characteristic plaid pattern, I start off by creating a series of vertical stripes that represent the four primary colors of the pattern.  I then lay out horizontal bands that cross directly over the vertical bands.  I use the same four primary colors and spray through a sanding screen, producing the blended color tones featured in the plaid print.  Finally, I add a band of dark color around the rails of the surfboard to form a frame of sorts.

For the striped version, I tape off three zones of the board; center, nose, and tail.  Within these zones, alternating colored bands of varying thicknesses are laid down to form the distinctive, classic pattern.

Onward to Glassing

Glassing is only achievable in incremental steps, similar to the process of shaping the foam of the board.  Glassing consists of four separate treatments of resin that constitute the glassing process; two laminations and two hotcoats.  A lamination is the process through which fiberglass cloth, saturated with resin, is bonded to the fragile foam core.  A hot coat is an additional layer of resin that helps protect the fiberglass cloth and completely seal the inner foam core.

Laminations

The first lamination occurs on the bottom of the surfboard.  To prepare for the lamination, the top of the board is taped and masked to avoid being exposed to resin prematurely.  A piece of fiberglass cloth is rolled out over the length of the board and is cut so that the fabric drapes over the rails, usually extending approximately 2-4 inches below the beginning of the rail.  Surf Pendleton and Blackfern decals and fin boxes are dry fitted to ensure that no mishaps occur.  The entire surface of the board is then “wetted out” with polyester laminating resin.  A squeegee is used to work the resin into the porous foam of the board and to fully saturate the fiberglass cloth.  The cloth is carefully wrapped over the rails and the board is left to harden or “cure”.

Once the bottom is cured, the board is flipped over and the same process is done to the top, this time with two layers of fiberglass cloth to add additional strength to the deck.  After wrapping the top layers of fiberglass onto the bottom of the board, the resin and fiberglass are left to cure once again.

Hotcoats

To hotcoat the board and finish glassing the board, another coat of polyester resin called sanding resin is applied to each side of the board.  This process is among the most simple of all the steps of surfboard fabrication – resin is poured out of a small pail and then spread evenly over the surface of the board with a large paint brush.  Each side is left to cure before flipping the board a final time to hotcoat the other side.

Hot coating produces a slick, imperfect surface.  In order to make it ready for use, every square inch of the board must be sanded.  Sanding makes the surfboard finally feel like a surfboard; smooth, strong, and perfect.  Many boards are considered finished and ready for use at this stage but the Pendleton boards receive one additional treatment – a gloss coat.

Glossing

The gloss coat is nearly identical to the hotcoat.  The only major difference in the processes is that the gloss coat resin is slightly thinner and is applied to a perfectly smooth, even surface.  As a result, less resin is required and a perfectly smooth surface is formed.  Even so, the entire board is sanded again to make it ready for use.  Successive sand paper treatments, each one higher grit than the last, are used to form completely smooth and scratch free surface.

Finishing Touches

To bring a shine to the finished product, buffing compound is applied using a woolen compounding bonnet.  Finally, a treatment of polishing compound is applied to all surfaces of the board using a polishing pad to give it a candy-like luster.

Launch

Tools and hands have passed over every square inch of this board dozens of times and, at last, this Pendleton Limited Edition Surfboard is ready to ride!  Get ready to catch some great waves!

 

 

The Heart of the Mountains

Russian VOGUE traveled to Central America for a dramatic editorial, “The Heart of the Mountains,” and they brought along some Pendleton beauty.

Below, a Pendleton Serape (in black) and Compass Stripe blanket:

WEB_RussianVogueSerape

 

And the Heroic Chief backpack in this shot:

Web_RussianVogueBackpack

Serape and backpack available at pendleton-usa.com.

 

 

Porter Magazine and the Basket Dance

Net-a-Porter’s third issue of Porter Magazine features our blankets in a beautiful way. Basket Dance and Spider Rock never looked so stunning.

Porter-1

 

Basket-Dance

 

Porter-2

 

Porter-3

 

All model shots courtesy  PORTER magazine.

Running a Rapid in the Grand Canyon by Greg Hatten

Time for another guest post from our friend Greg Hatten, in which he replicates a run from the 1962 trek down the Colorado River in the Grand Canyon. This one is exciting, so hold on.

We scout the big ones – the ones you can hear for a half mile before you can see – the ones that sound like a freight train when you stand beside them.  The ground trembles.  Their names are spoken with respect and dread around the campfire at night and over coffee in the morning… House Rock, Hermit, Hance, Granite, Bedrock, Crystal, Lava…

1_credit_-John_SchroederIzzy & I Scouting a Rapid   photo credit:  John Schroeder

Just above Granite Rapid at mile mark 94, we pull our boats to shore on river-left, tie up, and hike down the river over unstable river rocks to “scout”.    It’s rated a 9 + on a scale of 10 by Larry Stevens in his River Runner’s Map and Guidebook to the Colorado River – one of the most difficult on the river.  Halfway down this rapid is one of the largest and most violent holes we have seen on the trip.  We stop at the midpoint of the rapid to have a closer look.  We watch, mesmerized, as water pours over a huge boulder we cannot see and then dives ten feet down with so much force it creates a wall of water that slams back upriver to create a turbulent cauldron and a suck-hole that we must avoid.  We are transfixed and for a long moment we can’t look away.   I wonder to myself, if a boat got sucked into that, would it EVER come out?

Scanning the river for a possible path through the rapid (the “line”) we speak a boatman’s language of laterals, V-waves, pour-overs, eddies, and cheater lines.  There is a seriousness in our tone this morning as we dissect the rapid and discuss what we see.  I love the banter, I respect the experience, I trust the judgment of these teammates.

Two days ago my boat was swallowed and flipped in an ugly hole at Grapevine – a Class VIII.  My boat took a beating and so did my confidence.  It’s on my mind as the hole in front of us thunders away and we continue to search for the “line.”

There are big rocks all the way down the left side which appear and then disappear with the crashing waves.  At this low water level those rocks would tear our boats to pieces… left side is not open today.  We look at the middle run but everything coming down that V-wave is getting sucked into the hole-that-must-be-missed, so it’s not an option either.  The only path we see at this level is a far right run where a ridge of water is formed by the current careening off the canyon wall.  The run requires a boat balancing act on a tight wire of white water that’s uncomfortably close to the canyon wall.

2_credit_Dave_MortensonPortola popping out of the hole – Photo credit:  Dave Mortenson

The hard part is getting up on that water ridge in the first place.  There is a hole above the ridge on the far right side of the river formed by the first steep elevation drop.  If you can put your boat half in the hole and half out of the hole, it will pop your boat out and fling it right on top of the ridge for a twenty second thrill ride to the bottom.  Hit the hole too far right & you’ll get sucked into it.  Skirt the hole too far left and you’ll miss the ridge and be swept into the V Wave and the big dangerous hole we must avoid.

We are all agreed – it’s a far right run.

After the scout, it’s a quiet walk back up to the boats.  We are alone with our thoughts and visualizing our moves and I pose the question to myself… again… “why am I doing this”?

3_credit_Dave_MortensonPortola riding the ridge  Photo Credit:  Dave Mortenson

Robb goes first – he’s been rowing since he was four years old and makes every rapid look easy.  He gives us confidence as he hit the exact line we talked about and has a splashy ride down the ridge.  Perfection.  He pulls into an eddy below the rapid and sets up for rescue as a safety precaution.

Steph is next – he’s rowing the Susie Too – a remake of the original from 1962 and a twin hull of my boat, the Portola.  He takes the Susie Too over the first big drop and disappears.  His line is a little too aggressive – his boat is too far into the hole at the top.  The power of the hole grabs his right oar and almost pulls him out of the boat.  The force is so strong it springs the brass oar lock and releases the oar which is now useless in his hand.  He slams the oar back in place just as he gets spit out of the hole, a little sideways and twisted, but up on the ridge none-the-less.  A quick correction and he rides the ridge like a bucking horse although dangerously close to the wall.  Nice!!

4_credit_Izzy_CollettExploding wave   Photo Credit – Izzy Collett

I tighten my life jacket, put on my helmet, and row quietly to the other side of the river several hundred feet above Granite.  The approach to the infinity edge is slow.  Too slow.  Too much time to think about my disaster at Grapevine.  I snap back to the moment and reach the edge where I can finally see down the steepness of the other side and know for the first time that my alignment is spot on.

This is the nerve that Craig Wolfson talks about.  I’m lined up to hit one hole so I can miss a bigger hole and it’s only two days and twelve miles after almost losing my boat and my passenger in a hole that looks a lot like these.

5_credit_Izzy_CollettSliding down the backside   Photo Credit – Izzy Collett

I drop over the top and everything speeds up – now I’m racing for the edge of the hole on the right.  Half in half out – I hit it perfectly and I keep my right oar up away from the turbulence (thanks Steph).  I’m rewarded by a clean exit from the hole and a little air as I get deposited right on top of the ridge of water.  I ride the waves as they explode under my boat and shoot me down the other side.  The canyon wall is cozy and I feel like it’s inches away from the tips of my oars.  I go speeding by the hole-that-must-be-missed on my left. It’s so close I can touch it with my oar.

6_credit_Dave_MortensonSpeeding by the big hole – Photo credit:  Dave Mortenson

One more big wave at the bottom and it’s over.  In 20 seconds.  Wow…and then I remind myself – “THIS is why we do this!!”

That run at Granite restored my confidence – which would be tested repeatedly over the next 190 miles.  Three days later I would flip in Upset Rapid – Class nine.

 

7_credit_Dave_MortensonPortola flips in Upset – Photo credit:  Dave Mortenson

It had a bigger hole than Granite on the day it got me…but THAT’s another story.

8_credit_Dave_MortensonPendleton Blankets drying – Photo credit:  Dave Mortenson

You wreck a wood boat, you fix it.  You flip a wood boat, you dry out your blankets. And that’s how you run a rapid.

Coming up in Part III…read about night-life on the Colorado.  Ever wonder what it’s like to sleep in the canyon for a month or how we cook, clean, relax, and get re-charged for a challenging day on the river?  Read about it next week and enjoy some beautiful night-time shots in “Night in the Canyon”

 

 

Saturday May 17, TPC Sale– THE BIG ONE

05_17_14_TPC_Portland_Sale_SOCIAL_5 5_v24

Pendleton Woolen Mills Receives the Port of Portland’s 2014 Compass Award

compass-award-statue

When we opened our store at the Portland International Airport, we partnered with the Port of Portland, which oversees our city’s commerce by river, rail, road and plane. The airport location has given us a wonderful opportunity to share our very-Oregon brand with the rest of the country as it passes through PDX (which is what we call our airport, for you out-of-towners). The Port recognized our association with the Port of Portland 2014 Compass Award at the recent “Tradition of Trade” annual luncheon.

 

compass-award-certificate

 

The award recognizes the personal efforts of our company’s president, Mort Bishop, as well as Pendleton’s corporate support and involvement. Said Port Commission Vice President Paul Rosenbaum, “Like the points of a compass, their business partnership and confidence in local operations have helped us navigate and achieve key Port goals such as job creation and environmental stewardship.”

During the award presentation, Mr. Rosenbaum cited Pendleton as one of Oregon’s heritage enterprises, and applauded our focus on building positive relationships with Oregon’s tribal community—the original founders of trade in the Northwest. “Mort and his family have led the Pendleton enterprise for six generations,” said Mr. Rosenbaum. “Pendleton’s rich American heritage and deep roots in the Pacific Northwest is a source of pride for all Oregonians.”

Company president Mort Bishop accepted the Compass Award on behalf of Pendleton Woolen Mills. In his words, “100 years ago, there were over 1,000 woolen mills in this country. Today we operate two of only a handful that survive – Washougal and Pendleton. Our facilities are state of the art, providing American jobs, utilizing sustainable, environmentally-friendly practices, employing world class technology. Pendleton uses some of the world’s finest wool fleeces from right here in Oregon…from generations of the same ranch families for over 100 years.  When you buy a Pendleton, you are literally and metaphorically buying the fabric of Oregon.”

More than 500 business leaders, elected officials and community stakeholders attended this year’s Gateway to the Globe luncheon. It was quite an event, and the Compass Award is quite an honor.

Princess Carly in Avenue Magazine

Carly

 

Calgary Stampede Indian Princess Carly Weasel Child has been having an exciting year. Here she is on a shoot for Avenue magazine at the Blackfoot Crossing Historical Park on the Siksika Reserve, where Carly is from. She’s wearing a dress made by Janine’s Custom Creations with Pendleton wool.

We’re proud to help sponsor Carly. You can follow her on Facebook and Twitter as she travels throughout Europe and Canada as an ambassador for the Calgary Stampede.

Blackfern Boards x Pendleton, up close

As we head into the final days of our Surf Pendleton pin-to-win contest, we thought you’d enjoy an in-depth look at the making of the board you can win. So here, in their own words, are all the steps that go into making these fine boards–one at a time, all by hand.

This slideshow requires JavaScript.

Making the Pendleton Limited Edition Surfboard

Each Pendleton Limited Edition Surfboard is shaped, painted, glassed, sanded, and glossed by hand in Blackfern’s fabrication studio in Portland, Oregon.

Retro Styling

For the Pendleton Limited Edition Surfboard, a 1960′s era single fin model was chosen.  This timeless retro board embodies the lifestyle of the era; clean, simple, and stylish.  Many of these retro shapes are having a resurgence in popularity because of their versatility in a range of surf conditions.  The board style pays homage to an era in which Pendleton was a vibrant force in Californian surf culture.

The Process Starts

The first step in the fabrication process is to trace out the outline of the board onto a blank, which is a rough-cut piece of foam that resembles a surfboard, albeit not a very functional one.  The outline is cut out of the blank, not unlike making Christmas cookies, and the excess foam is removed.  The outline is then tuned by a rasp-like tool called a surform, in order to hone the perfect curve that will define the finished board.

From Bottom…

The next step is to craft the bottom of the board.  This process begins by power planing or “skinning” the protective outer shell of the blank that protects the softer foam within.  After the skin is removed, the bottom contours are shaped in by removing material with additional passes with the power planer, surform, and finally, sanding blocks.  The single fin model features shallow concavity through the middle of the bottom, blending into a V contoured tail.  These contours give the board a loose and nimble feel with higher performance than would be achievable with a flat bottomed board.

…To Top

At this point it is time to flip the blank over and begin working on the top of the board.  Similar to the bottom, the first step is to remove the protective skin of the blank.  During this process,  I start to flesh out the top contours and the “foil” of the board.  Foil refers to the changing thickness, both from the center towards the rails as well as from the tip to the tail of the board.  It is during this process that a shaper’s ability to visualize in three dimensions becomes crucial.  Knowing where to remove material and in what quantity can be tricky.  The goal is to produce a smoothly foiled board; maintaining volume in helpful areas and removing it where unneeded.

Forming the Rails

After the top has been shaped and foiled, its time to move onto the rails of the surfboard.  At this point the board has a functional top and bottom but with its boxy, vertical rails, it would be miserable to surf.  To form a smooth curving rail, I begin removing rail material in the form of rail “bands.”  Bands are sloped ridges that run the length of the board; thickest at the middle and thinner towards the tip and tail.  By removing rail material incrementally in these stepped ridges, it is possible to produce a rail that changes shape and thickness in a controlled and consistent fashion.  Once the bands are crafted to satisfaction, the board is turned onto its rail and I begin passing a sanding screen over the ridges of the “bands.”  After screening repeatedly, the ridges disappears and a smoothly curving rail emerges.

Finishing Foam Touches

The final steps of the shaping process are to install the slider single fin box and to finish sand the entire shaped surfboard to a buttery smooth finish.  The board is signed off to the customer who ordered it.  I write the customer’s name, the dimensions of the board, and finally “Pendleton Surf Limited Edition.”

Getting that distinctive Pendleton look

The specialized Pendleton artwork is applied before glassing the board.  The two color versions vary on their preparation.  To produce the characteristic plaid pattern, I start off by creating a series of vertical stripes that represent the four primary colors of the pattern.  I then lay out horizontal bands that cross directly over the vertical bands.  I use the same four primary colors and spray through a sanding screen, producing the blended color tones featured in the plaid print.  Finally, I add a band of dark color around the rails of the surfboard to form a frame of sorts.

For the striped version, I tape off three zones of the board; center, nose, and tail.  Within these zones, alternating colored bands of varying thicknesses are laid down to form the distinctive, classic pattern.

Onward to Glassing

Glassing is only achievable in incremental steps, similar to the process of shaping the foam of the board.  Glassing consists of four separate treatments of resin that constitute the glassing process; two laminations and two hotcoats.  A lamination is the process through which fiberglass cloth, saturated with resin, is bonded to the fragile foam core.  A hot coat is an additional layer of resin that helps protect the fiberglass cloth and completely seal the inner foam core.

Laminations

The first lamination occurs on the bottom of the surfboard.  To prepare for the lamination, the top of the board is taped and masked to avoid being exposed to resin prematurely.  A piece of fiberglass cloth is rolled out over the length of the board and is cut so that the fabric drapes over the rails, usually extending approximately 2-4 inches below the beginning of the rail.  Surf Pendleton and Blackfern decals and fin boxes are dry fitted to ensure that no mishaps occur.  The entire surface of the board is then “wetted out” with polyester laminating resin.  A squeegee is used to work the resin into the porous foam of the board and to fully saturate the fiberglass cloth.  The cloth is carefully wrapped over the rails and the board is left to harden or “cure”.

Once the bottom is cured, the board is flipped over and the same process is done to the top, this time with two layers of fiberglass cloth to add additional strength to the deck.  After wrapping the top layers of fiberglass onto the bottom of the board, the resin and fiberglass are left to cure once again.

Hotcoats

To hotcoat the board and finish glassing the board, another coat of polyester resin called sanding resin is applied to each side of the board.  This process is among the most simple of all the steps of surfboard fabrication – resin is poured out of a small pail and then spread evenly over the surface of the board with a large paint brush.  Each side is left to cure before flipping the board a final time to hotcoat the other side.

Hot coating produces a slick, imperfect surface.  In order to make it ready for use, every square inch of the board must be sanded.  Sanding makes the surfboard finally feel like a surfboard; smooth, strong, and perfect.  Many boards are considered finished and ready for use at this stage but the Pendleton boards receive one additional treatment – a gloss coat.

Glossing

The gloss coat is nearly identical to the hotcoat.  The only major difference in the processes is that the gloss coat resin is slightly thinner and is applied to a perfectly smooth, even surface.  As a result, less resin is required and a perfectly smooth surface is formed.  Even so, the entire board is sanded again to make it ready for use.  Successive sand paper treatments, each one higher grit than the last, are used to form completely smooth and scratch free surface.

Finishing Touches

To bring a shine to the finished product, buffing compound is applied using a woolen compounding bonnet.  Finally, a treatment of polishing compound is applied to all surfaces of the board using a polishing pad to give it a candy-like luster.

Launch

Tools and hands have passed over every square inch of this board dozens of times and, at last, this Pendleton Limited Edition Surfboard is ready to ride!  Get ready to catch some great waves!

 

 

“The Pendleton” featuring Luke Ditella for PONYBOY

Luke-Ditella-SPREAD-11F

We’re just a little bit crazy for these images shot by PO­­­NYBOY featuring Luke Ditella in vintage Pendleton wool shirts. Luke is a surfer (read about him at The Surfer’s View ) who works with Click Models NY.

Luke-Ditella-SPREAD-4F

As the magazine says, “We were pleased to feature Luke, and his rugged good-looks worked so well for this story.” He models an array of classic Pendleton plaids from tartan to exploded to ombre to check to glen to windowpane, shown tucked into high-waisted vintage wool dress slacks.

Luke-Ditella-SPREAD-2F1

And, he wears a solid wool shirt reminiscent of the Tony shirt we have at pendleton-usa.com this spring.

Luke-Ditella-SPREAD-5F

Based on the plaids and lengths of the collar points, we see shirts from nearly every decade we’ve been making wool shirts in our nine decades of quality shirtmaking. Check out our Instagrams tagged #pendleton9decades to see some of the recreated shirts we’re doing this fall to celebrate. And you can follow Luke’s Instagram at LUKEDITELLA.

See the full Ponyboy feature here with many more shirts.

 

Surf Pendleton – Win a Custom Board by Blackfern!

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WIN THE ULTIMATE RIDE - A CUSTOM PENDLETON SURFBOARD

To celebrate its surfing roots and the new collection, Pendleton is hosting the Pin-to-Win Surf Pendleton Contest March 17 – April 28, 2014. Grand Prize is a custom Pendleton Surfboard in the original surf plaid worth $1200; Second Prize is a $400 Pendleton gift card; and Third Prize is a $200 gift card. Contestants enter online using their Pinterest account information.

BLACKFERN SURFBOARDS,

A ONE-OF-A-KIND COMPANY

Blackfern Surfboards is a backyard board company based in Portland, Oregon. Started in 2008, it possesses a distinctly Oregon ocean-meets-the-forest aesthetic. The company creates one-of-a-kind custom surfboards designed in collaboration with each customer. Each board is handmade in Portland by local wave-obsessed surfers.

SURF VISIONARY MIKE HALL

Waves off the rugged Oregon coast are like no others on earth. After much frustration with boards that were not suited to Oregon’s choppy waves, veteran surfer Mike Hall decided to shape his own board – and the rest, as they say, is history. With much trial and error, he found a set of design characteristics that perform well in Oregon’s unique waters. After designing boards for a few friends, Mike devised the Blackfern concept – a grassroots effort to put locally made custom boards into the hands of those who venture into the Pacific Northwest surf.

THE MAKING OF A PENDLETON BOARD

In tribute to a time when Pendleton was a vibrant force in the California surf culture, a 1960s-era single-fin model was chosen. This timeless retro board embodies the lifestyle of the era – clean, simple and stylish. From start to finish, each is a handmade work of art – shaped, painted, glassed, sanded and glossed by hand in Blackfern’s fabrication studio in Portland.

  • The first step is to trace the outline of the board onto a blank, which is a rough-cut piece of foam.
  • Next the bottom is crafted, then the top is shaped and foiled.
  • Then the rails are formed and the final shape begins to emerge.
  • The final steps of the shaping process are the installation of the slider single-fin box and a sanding to a buttery smooth finish. At this point, Mike writes the customer’s name, board dimensions, and “Pendleton Surf Limited Edition” on the board.
  • Next the Pendleton plaid or stripe pattern is applied.
  • Then comes glassing – a four-step process that consists of two laminations and two hotcoats.
  • Finally, a gloss coat is applied and buffed to a candy-like luster.

Tools and hands have passed over every square inch of the board dozens of times.

MAKING THE PENDLETON
LIMITED EDITION SURFBOARD

By Michael Hall, Blackfern Surfboards

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