So... after Sandy wrecked everyone's place in my neighborhood we were flooded with contractors and sales reps for all sorts of home rebuilding stuff and one thing some sales rep showed up with stuck in my head..... its was this guy coming around with sprayfoam insulation. when it dried it was hard as a could be and can be cut and sanded, I know because I tried this on the block square sample he left....

(Before you read... keep in mind I have no clue on building boards...)

I eventually got around to thinking that some backyard/garage macguyvers could use this to recreate a surfboard, up to the point of glassing...

here's what I was thinking.... take your board you want to recreate and (for arguments sake) paper mache the board... 2 halves (left side/right side), nose to tail. when it dries you have the mold of your surfboard. then fill the 2 molds with spray foam. when it dries take it out of the mold and glue the two halves together. I guess one could expect to do some fine tune sanding.... then glass it????