Leg Guard/ Fenders for Adaptable System on Prone Adaptive Surfboard

This Jabali 5'4" wooden surfboard has been retrofitted with US fin boxes on the deck, allowing prone adaptive surfers to add and personalize various attachments. This setup makes it easier to test and use different attachment configurations.

leg guard are the second of three attachments I designed for this system, with a focus on sustainable materials and creating an accessible design that is easily replicable and adaptable to the surfer’s needs.

You can find the other attachments and components on my profile.

This project was part of research on adaptive surfing conducted at the University of Ghent for my Master’s thesis. If you have any questions, feel free to contact me at charlie.debreuck@gmail.com.

1. Cork acoustic insulation board (10 mm): A water-resistant, biobased material suitable for use in marine environments.
2. Adhesive suitable for ocean environments: Make sure to use a waterproof adhesive—note: standard wood glue will delaminate when exposed to water.
3. Multiplex plywood (4 mm): Used for structure or reinforcement.
4. Hole saw (10 mm): For drilling clean circular holes in the cork or plywood.

The goal is to create two wedge-shaped leg guards from one block, to minimizing material waste.

Cut out six layers of 10 mm cork insulation board, each measuring 100 mm × 150 mm.

Glue the six layers together using an adhesive suitable for ocean environments to form one solid cork block.

After the glue-up, clean the edges by sanding them smooth. Then, drill 10 mm-wide slots through the entire block these will serve as channels for the washers and bolts used to secure the guard.

To strengthen the leg guard and provide a solid structure for tightening the bolts, add a rigid backing layer. Use materials you have on hand to avoid purchasing new ones, leftover glass epoxy or similar materials work well.

In this example, I glued a 4 mm plywood sheet to the bottom of the cork block, with the cork facing outward. This creates a sturdy core while keeping a soft surface in contact with the board.

Cut the cork block in half through the middle to create two similarly shaped leg guards. Then, round off the edges to reduce the risk of the cork chipping or breaking off during use.

Drill slotted holes in the backing layer to fit M6 bolts. These will allow for adjustable positioning and secure attachment to the board.

Enjoy your adjustable leg guards, and feel free to customize them to best suit your surfing style and needs.