my bud and I just finished two small wave boards this summer. He's a bigger dude and made a 6'3 PU/PE swallow tail quad and I made my third attempt at a mini simmons type shape. Its 5'8 EPS/Epoxy. Here's a little bit about the process: both templates were just cardboard shapes scabbed together from other boards:
Shaped Mini Simmons in the background, swallow tail template on blank about to be cut:
Cutting the outline with a jigsaw:
Cleaning up the curves with some sandpaper glued to a block of wood. This is a really critical step IMO.
Cutting the rail bands:
<br />Tuning the rails with some drywall screen:
The ghetto 20 year old O'Fishl jig that still works perfectly for Futures Boxes: