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Sorry if I've got this wrong but it sounds like your new to shaping, there are several different ways that mordern surf board are constructed, ranging from hand-made customs and custom-compasites to foamies and pop-outs (like bic boards). It might be helpful if you check out the buyers guide on croyd's little pink surf shop web site as it gives basic info on the different methods of construction. If your looking to make a your own board this would be a custom, normally you would 'shape' a large foam blank, though you may be able to find laser cut, CNC, or pop-out blanks ready for you to sand, add art work or stickers and glass.
If you shape you own blanks these would be larger than the finished board and be planed and sanded down to size. To get boards the same shape you would use templates and calipper, though it's an art not an exact science which is part of the joy of making a custom board.
It would be difficult to cast your own blanks as they are made from special more dense foam in presurised moulds, also if you were to take this from an existing board so a finished board larger than the original once glassed.
If you were thinking of casting a board out of resin the it would be too heavy to surf, its the foam core that gives the board its bouancy.
I'm only just starting out learning how to shape, but I know that there is no quick and easy. It take time to learn the skills, and there's a lot of trial and error involved when starting out. It also takes time and effort to shape a board and it should be a labour of love from start to finish not a way of making a quick buck.
maybe start out by repairing a second hand baord if your looking for a cheap altenative, or buy a bic board,
But I like your experimental way of thinking don't let me put you off why not give it a go any way and let me know how it goes, its only through progressive faward thinkers that take these risks that we evolve our sport.
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