Board Construction

Crowd Control Kevlar Flex Construction

After more than five years of testing and development, we’ve created a durable, lightweight surfboard construction designed to deliver an exceptional flex pattern for the epoxy surfboard rider.

Crowd Control Surfboards’ Kevlar Flex starts with a 1.5- or 2-pound EPS stringerless foam blank featuring a recessed 2-inch, 7 oz. 100% DuPont™ Kevlar® strip running from nose to tail along the bottom of the board. This construction allows the board to maintain a controlled amount of flex while providing an extreme level of durability, even with a lighter overall lamination schedule.

The deck utilizes a dual-twill Kevlar® and carbon-fiber hybrid weave—the same type of advanced composite technology used in the aerospace industry and high-performance racing boats. This hybrid reinforcement provides exceptional crush and dent resistance while maintaining the strength necessary to withstand repeated flex, pressure, and impact.

We offer two primary glassing options:

SUPER LIGHT PERFORMANCE
• 4 oz. S-cloth bottom
• 4 oz. S-cloth deck over the dual Kevlar®/carbon reinforcement
• Extremely lightweight and responsive

MAXIMUM DURABILITY
• 6 oz. S-cloth bottom
• 6 oz. S-cloth deck over the Kevlar®/carbon hybrid
• Built for exceptional longevity, durability, and impact resistance while still maintaining a surprisingly light overall weight

Personally, I’m not a fan of ultra-light surfboards. I’ve built several boards with a slightly heavier lamination schedule to replicate the feel and weight of a traditional polyester board—and the results have been amazing. They retain the responsiveness and durability of the epoxy/Kevlar® construction while delivering a familiar, solid feel underfoot.

Built to flex. Built to last. Built to shred.

As with most dark-colored boards and epoxy constructions, avoid prolonged exposure to direct sunlight and extreme heat. Never leave the board in a hot vehicle or enclosed space for extended periods.

Crowd Control Carbon Flex

Crowd Control’s Carbon Flex construction is engineered around the same proven layup philosophy as our Kevlar Flex, with carbon fiber reinforcement strategically integrated to deliver a responsive blend of strength, flex, durability, and lightweight performance.

The primary difference is the reinforcement material and placement. The Carbon Flex uses a 2-inch-wide, 4 oz. carbon-fiber strip running along the bottom of the board, while the deck is reinforced with a 4 oz. or 7 oz. carbon-fiber laminate, depending on the rider’s desired weight, flex, and durability characteristics.

Carbon fiber provides an exceptional strength-to-weight ratio and helps create a lively, responsive flex pattern. The increased stiffness and rapid recovery of carbon reinforcement can give the board a quick, energetic feel through turns, bottom turns, and other high-load maneuvers, while helping the board maintain its structural integrity over repeated flex cycles.

Every Crowd Control Carbon Flex board is laminated and finished according to the rider’s desired final weight and performance characteristics. Rather than using a one-size-fits-all glass schedule, we can adjust the construction to achieve the balance of lightweight performance, flex, strength, and durability that each rider is looking for.

One construction. Different levels of performance. Built around the rider.

Standard Polyester & EPS Construction

At Crowd Control, we offer quality construction options for both traditional polyester/polyurethane (PU) surfboards and modern EPS/epoxy boards, allowing us to tailor the board’s weight, flex, durability, and overall feel to the individual rider.

Our standard layup for both polyester and EPS surfboards consists of a 4 oz. bottom laminate and a 4 oz. + 6 oz. deck laminate, utilizing BFG Technologies Warp Glass. This proven construction provides a balanced combination of strength, responsiveness, and durability while maintaining the natural feel and performance characteristics surfers expect from a well-built board.

For riders looking for additional performance or durability, we also offer E-Glass and S-Glass upgrades. S-Glass provides increased tensile strength and stiffness compared with conventional E-Glass, making it an excellent option for surfers who want a stronger, more responsive construction without adding unnecessary weight.

Polyester / PU Construction

Traditional polyester surfboards remain popular because of their familiar flex pattern, smooth response, and classic feel underfoot. The polyurethane foam blank combined with polyester resin produces a distinctive ride that many surfers describe as having a natural, dampened flex and a smooth connection with the wave.

Polyester construction can be particularly appealing to riders who prefer a more traditional surfboard feel, while still allowing us to customize the glass schedule to achieve different levels of weight, flex, and durability.

Custom Glass Schedules

Not every surfer wants the same board. That's why we offer different glass schedules and reinforcement options based on the customer's requirements. A lighter schedule can produce a lighter, more responsive board, while additional layers can increase durability, stiffness, and resistance to everyday wear and tear.

Whether you're looking for a traditional PU/polyester feel, a lightweight EPS/epoxy construction, increased durability, or a specific flex pattern, we can adjust the materials and laminate schedule to build the board around the way you actually surf.

Your wave. Your style. Your flex. Your board.