Products

How to Order a Custom Vortex


Choosing a Custom Vortex

As a Vortex Custom Board is built to your personal specifications, it can be dialed in to suit your physical build and surfing requirements. Whether you are ordering your first custom or a for a board quiver for an Indo adventure, Brian and a hand of elite shapers can talk you through every step of the process. The relationship between the shaper and surfer is a fundamental dynamic you simply don’t get with stock boards. World champions have benefited from Brian’s extensive experience, and you can too. Call, e-mail or drop by the factory to discuss your next board with a Vortex shaper personally.

Designing your Vortex Custom Board once you have the dimensions and features dialed in, not only do you have the freedom to select your own custom color combination and stamp placement, with Vortex wide range of stamps you can set your board apart from the aesthetic boredom of normality.


Riding Style

By specifying your riding style, your custom shaper can choose a curve that best suits your specific needs.

Length

(Normally Between 38-46 inches) This is the overall finished length of your board. The general rule of measuring from the floor to your belly button doesn’t always hold true. The best way to find out what length is best for you is to have a go on friend’s boards until you find what works. Below is a general guide based on a rider’s height and weight to help you select the best board length for you.

Height (inches) Weight (pounds) Board Length (inches) Height (cm) Weight (kg) Board Length (cm)
4'-5' 65-85 lbs. 36"-38" 153 28-55 123
4'6" - 5'2" 85-115 lbs. 39" 155 30-55 130
5'3"- 5'6" 110-130 lbs. 40" 155 35-55 135
5'7" - 5'9" 125-170 lbs. 41"-41.75" 158 38-58 137
5'9"-6'0" 145-180 lbs. 42" 162 40-60 140
5'10"-6'2" 160-190 lbs. 42.5" 165 42-65 147
6'1"-6'3" 170-210 lbs. 43" 167 42-72 157
6'2"-6'4" 180-270 lbs. 44" 170 50-80 158
6'3" - 6'6" 195-255lbs. 45" 173 55-85 160
6'4" + 200lbs + 46" 179 60-90 165
      183 65-95 168
      190 65-100 170
      195 70-105 172

Nose Width

(Normally between 10.5 - 15 inches) This is the finished nose width of your board, including rail skins. A narrow nose is good for drop knee riding and is also highly maneuverable when riding prone, though too narrow will make the board unstable around the front of the board and cause you too catch a rail.

Width

(Normally Between 20.5 - 23 inches) The type of waves you will be surfing generally determines the overall width of the board. Wider boards work best in small, weaker surf as they provide more flotation to get you through the sections. Narrower boards are suited to bigger, more powerful waves. This is due to the fact that in the heavier stuff, you are looking to control the force of the wave. A good rule of thumb is to multiply the board’s length x 0.506 to get the width e.g. 41.5" x 0.506 = 21"

Wide-point Distance from Nose

(Normally Between 12-24 inches) This is the distance from the nose to the widest point of the board. The distance from the nose will determine the overall look of the board and the template that will best suit the Dimensions you have requested.

Rail Ratio

Rail Ratio - This is the ratio of bottom rail to top rail and is expressed in percentages. For example, 50/50 bottom/top rail is an even 50% top to 50% bottom rail (chine). Best for smaller, lighter riders in small surf. 60/40 bottom/top rail is 60% bottom rail and 40% top rail (chine). High performance riders in powerful surf used the original standard rail set-up.

Tails

Tail width plays an important part in the performance of your board. A narrow tail will make the board loose and easy to release for spins and quick turns. A wider tail will pick up speed faster than a narrow tail, but is harder to turn. The width of the tail must also be wide enough to support the weight of your hips and legs. If you are not sure about your tail width, a rule of thumb for the tail is to divide the length of the board by 2.33 e.g. 42"/ 2.33 = 18.25"

Bat Tails

Bat Tails work best in waves over 2-3 feet and are based on two principles:

  1. The Bulb “or" Hump - By increasing the surface area though central tail area of the board, the weight of the rider is more evenly distributed. This helps to reduce body drag during take offs and on speed drives down the line. By reducing body drag, board speed is maximized.
  2. The Wings - Each wing of the bat tail design is like a mini crescent tail. By positioning the tips of the wing at a point shorter than that of the bulb, this effectively shortens the length of the rail making the board looser, perfect for quick spinning moves around the pocket.

When turning both the bulb and wing come into play as force is applied to both areas from the rider’s hips as they draw a smooth line through the turn. It is here that the design of the bat tail is critical. If the tail design causes the rail to be too short, then the board can spin out.

Brian has experimented with countless bat tail configurations and through feedback from the world’s top riders, so Vortex offers a few variations of tail designs that work.

  1. Square Bat Tail - The squared bulb on this tail releases quicker for spins and transitional turns in and around the barrel
  2. Round Bat Tail - The full rounded bulb on this design gives maximum planning surface for all out speed, both at the take off and down the line.

Clipped Crescent Tail

The clipped crescent works in all surf conditions and features a symmetrical arc cut on a predetermined angle into the tail end of the board. The top of the tail provides the prone rider with a comfortable recess in which the rider’s hips and legs are unrestricted from movement.

The tail blocks are the pivot points for bottom turns and hard carves. If the blocks are too wide, the surface area of the block can offer too much resistance causing the tail to slide out. If the blocks are too small, the tail can dig

In causing the board to bog and loose speed. Todd shapes each clipped crescent tail individually, with the optimum sized ratio of tail arc to block width.

The clipped crescent is versatile and works well for the part-time DK rider. The back foot of the Dike’s can be forced into the top corner of this tail for more direct control in the turns and snaps.

DK Crescent Tail

Purpose built for the DK brigade, the DK crescent features smaller tail blocks and a larger arc radius. When prone riding, the rider relies on their legs to assist in the turn. The DK’er doesn’t have that luxury and must drive harder off the tail block and lower rail to hold an edge throughout the turn. In this case a smaller tail block is preferred to increase the penetration into the wave face. The larger arc allows the tail to release quickly once back foot pressure is relaxed, which enables the DK’er to bring the tail back around after heavy snaps.

Brian Peterson finds this tail superior to the full crescent tail previously offered to DK riders, as the sharp point of the full crescent is easily damaged which counteracts the benefits of the design.

Channels

When holding a line in the face of the wave or jamming a hard turn, there is only a relatively small percentage of the board in contact with the water. The section of the board that is in contact with the wave is generally the back corner. In fluid dynamic terms the area in contact is called “wetted area". Before the invention of the channel, the problem that faced shapers and riders alike was how to increase this wetted area?

1st generation riders like JP Patterson and Ben Severson helped design and pioneer the channel. The function of the channel is to increase the surface area of the slick exactly where it’s needed, thus increasing the wetted area. Its mathematical fact that the shortest distance between two points is a straight line. If you draw a curve between those same two points, the distance increases. If we take that example and apply it to the channel, the greater we draw the curve (or in the Bodyboards case, the deeper we sand the curve) the greater the distance between the two points. This distance equates to surface area. By placing the channel close to the rail and in the back corner of the board, this has enabled shapers to increase the wetted area in that section of the board, maximizing contact with the wave. This has increased the rider’s ability to hold a higher line on the face of the wave and to apply more power to turns.

Another function of the channel is that it directs the flow of water along the edge of the rail. A good example of this is to picture a fast flowing river. If you were to place a flat bottom board on top of the water and against the flow, then turn the tail from left to right; the board would turn relatively freely. If you were to do the same thing with a board featuring channels, there would be more resistance to the turns as the water is now flowing up through the channels.

The same thing happens with the channel in the face of a wave. As the rider and board are traveling against the flow of the wave, the water is directed through the channel, acting somewhat like a fin and further enhancing the rider’s ability to maintain a higher line and greater edge control.

Channels can be overdone. To deep and the board will grip too much causing a loss in speed and a possible trip over the falls as a result of being caught too high up on the wave face. The same can be said about channels that are too wide. Too wide and too deep and your board will go lie like a car with square wheels. The positioning of the channels is just as critical. If the channel is set too close to the rail, this can distort the rail line. If the channel is set too far from the rail, the channel will not function as intended.

As each Vortex Custom board is shaped by hand, the channel placement is completely precise on every board. We offer two channel designs, tested extensively by the world’s top riders in the most intense waves possible. Each has a specific benefit to improve the performance of your board.

Vortex Concave System (Single & Multi Concave VCS)

Vortex Concave System Top Secret Technology!!! Now using our exclusive CNC manufacturing technology, Vortex can precision shape the concave into the hull, resulting in a board that is unrivalled in both speed and edge control. Vortex's exclusive rail-to-rail concave on the board's bottom surface produces a faster ride and superior tracking. Design available in the Vortex single concave and Vortex double (multi) concave. Vortex's VCS is the next level in bodyboarding design.

Stringers

Flex-Recoil Stringer System

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With Vortex’s stringer technology the Flex-Recoil stringer is set into the center of the boards core. The main principle of the Flex-Recoil stringer lies in the flexural properties of the tube itself. When the rider pulls up on the nose of the board, the upward force is transferred through to the stringer. As the tail of the stringer is centrally anchored in the board, only the front of the stringer bends to conform to the shape of the board. This creates tension between the front and rear ends of the stringer, an action that is encountered during most turning maneuvers. Once the rider releases the pressure from the front of the nose, so to is the applied pressure released from the stringer. This causes the stringer to instantly recoil back to its straight profile and further enhances the board’s ability to project down the line. Flex-Recoil stringers also have the added benefit of helping to maintain a flat rocker profile.

Flex-Hinge Stringer System

Exclusive to Vortex USA, our new Flex-Hinge Stringer is the answer for those riders who demand the integrity of a stringer but still want regular nose flex. This unique attribute is achieved with the breakthrough technology of our precision milled Flex Hinge (patent pending). Constructed from a pliable rubber-like polymer, the Flex Hinge is specifically designed to allow for optimum flex in the nose of the board. Another feature of the two-part Flex-Hinge Stringer system is that the rear section of the stringer is shorter than a regular stringer, which makes it stronger as a result. This helps to increase the stiffness of the board where the most force is applied, from the elbow and hips and where most creases occur.

Vortex’s Flex-Recoil and Flex-Hinge Stringers are constructed from the finest grade composite fiber. With a wall thickness of .625", the stringers facilitate just the right amount of flex. Both single and double stringer options are available.

Please Note: Neither the Flex-Recoil or Flex-Hinge Stringers will not prevent board creasing.

Flex Mesh

A diamond shaped plastic weave, Flex Mesh is thermo-fused in between the boards core and Surlyn™ bottom. The uniform spaces of the mesh enable the core to bond directly to the Surlyn™ producing a unique structural advantage that not only stiffens the board with minimal weight increase, but changes the pre and post stress profiles of the boards two lamination stages. To equalize the increased tension the mesh causes after bottom lamination, more tension must be applied during the deck application. By balancing the tension between the two opposing surfaces, two things happen:

  1. The board has a flat rocker profile
  2. The board’s recoil/ memory properties are increased

Both of these effects undoubtedly improve the performance of the board. Another advantage of the Vortex Flex Mesh is that the layer covers the entire bottom surface of the board, delivering a more even flexural nature to the board. Vortex Flex Mesh stiffens both Dow™ PE and Pactiv™ PP cores to a medium level. We recommended either our Flex-Recoil or Flex-Hinge stringer system for maximum board life. Try the Vortex Flex Mesh and Stringer combo for the ultimate in performance reinforcement.

Finger/Hand Bulbs

Slick Bulbs

Raised nose grips hand shaped into the corners of the Surlyn™ bottom, ergonomically formed for fingertip control.

Deck Bulbs

Raised nose grips placed on the top of the core, under the deck skin, to fit perfectly in the palm of your hand.

Deck Contours

Elbow Pads

A full length, slim-line foam insert, fused in between the deck and core. The pad helps to protect the core by absorbing repetitive elbow impact in much the same way the soft foam inner of your shoe cushions your feet from the harder rubber sole. The contoured shape of the panel is designed to lock in the rider.

Elbow Lock

Recessed deck profile that locks in the elbows and forearms for better transfer of upper body torque.

Full Body Lock

A Full-length recess that locks in the elbows, forearms, and hips for ultimate body positioning.

Impacted Nose and Tail Bumpers

WaveDeck™ IXLPE

Protective Guards two areas of the board that are subject to impact damage are the nose and tail seams. The constant pulling up on the corner of the nose by the rider and damage as a result of leash wrap can cause the nose seam to deteriorate and split. The tail seam also gets a battering from knee drive pressure during duck-diving, not to mention abrasion and impact to both seams from contact with sand, rocks and other unfortunate collisions.

By heat fusing an impact resistant, IXLPE (crosslink) foam, directly to the Surlyn™ bottom and then wrapping the deck skin over the nose and tail contours, Vortex creates the IXLPE Protective Guard layer. Not only does the layer help absorb the impact and boost the seam strength, the direct bond to the Surlyn™ greatly improves the seal helping to prevent water from penetrating the core.

Decks

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At Vortex We stock a wide range of colors for both decks and rails and will be introducing special runs of custom colors for 2006. Colors change periodically and are subject to availability.

Sealed Air Cellu-Cushion™

Vortex and Brian’s exclusively uses Cellu-Cushion™ 8lb 3/16" PE deck skins on all Vortex custom Boards. Sealed Air™ USA constantly produces the finest grade skins available and although it is more expensive than other grades of PE skins, Vortex and Brian drive and interest is only making the best boards possible, not the cheapest.

Sealed Air Cellu-Cushion™ 8lb has a tight, uniform cell structure and bonds perfectly to Dow cores via our custom built Peterson/Bollar Tech laminator. Combined with Dupont Surlyn™, these boards are the ultimate Dow™ boards on the market.

With the advancement of our new, exclusive polymer coating, Vortex is now able to direct laminate Cellu-Cushion™ to Pactiv PP cores. This negates the need for backing layers and provides a stronger deck composition for improved board stiffness. Synergized with Surlyn™ and you have the complete package.

Cores

Dow™ 2.2pcf Polyethylene

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Dow™ PE has been the industry standard core for over 30 years. First used due to its flexible nature, relatively low cost and ease of heat lamination with other PE based materials, the performance attributes of Dow™ PE only came to the fore when combined with the Surlyn™ slick bottom. A triple layered sandwich construction of 8lb PE deck, Dow™ PE core and Dupont Surlyn™ revolutionized performance bodyboarding in late 80’s. This same construction combo is still at the forefront of professional bodyboarding today.

The flex attributes of Dow™ PE allow the rider to contort and manipulate the board to harness the power of the wave and transfer that power into projection. As the rider drives into a bottom turn, the downward gravitational force of the rider is opposed by the upward draw of the wave causing a projection of the bodyboard that all maneuvers founded. The projection is a result of the release from the opposing forces and the board’s ability to instantly recoil to its pre-set flat rocker profile.

Dow™ PE

Is the core of choice for those who surf in colder water climates and riders who like a little more flex then the Pactiv™ 1.9pcf Polypropylene

Pactiv™ PP

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Is the world’s premier Polypropylene bodyboarding core manufactured in the USA, it is the latest revolution in core technology.

Polypropylene is typically far stiffer than PE when compared at an equal density. At a comparable density to that of Dow™ PE = 2.2 pcf (pounds per cubic foot), PP is too stiff for use as a bodyboard core. This has allowed the foam techs at Pactiv™ to reduce the density by over 15% to 1.9pcf and still produce a superior, stiffer blank. The reduction in density also reduces the finished weight of the board considerably.

The construction technique of heat laminating outer skins to the PP core is far more intricate than that of Dow™ PE. As PP does not directly bond with PE, various substrates must be used to create multi-layered skins for this specific purpose. Vortex’s lamination process is a top-secret affair, but we can tell you that it’s one of the most advanced systems in the world.

Though PP core will tend to power through choppy surf due to its stiff nature. Perfect for warm water climates and water temps, PP core is for riders who like a more rigid platform for today’s high performance maneuvers.

Bottom Skins

Surlyn™

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Dupont™, the same company that brought us Teflon™, Nylon™ and Lycra™, invented the Surlyn™ resin. Initially used as a cover for golf balls due to its unique abilities to resist cutting and abrasions from golf club impact, some bright cookie at Morey Boogie decided to try it as a bottom skin on bodyboards. With its rubber-like properties, Surlyn™ provided the Bodyboard with a tough slick skin with precise flexural stiffness. This worked in perfect harmony with the boards core and top skin and gave the boards what they had been missing, rigidity. With rigidity came speed, which propelled the bodyboard from a soft toy into a high performance wave-riding vehicle. The rest, as they say, is history. Vortex uses Dupont Surlyn™ exclusively on all Custom boards (unless specified in your order). Nothing else comes close.

HDPP

High Density Polypropalene Bottom Skin is an additional bottom skin option for custom boards.

Inner Rails

WaveDeck™ IXLPE

All Vortex customs are double railed with an inner strip of super fine celled, WaveDeck™ 4mm 8lb IXL crosslink and an outer strip of Sealed Air Cellu-Cushion™ 8lb 3/16" PE (Unless specified in your order). The WaveDeck™ IXLPE inner rail forms a supreme bond to the boards core, deck skin and, Surlyn™ bottom, encasing the core with a virtually waterproof barrier.

Surlyn is now available in multiple colors. Email for availability. Colors change periodically and are subject to availability.

Outer Rails

Sealed Air Cellu-Cushion™

All Vortex Custom Boards feature Sealed Air™ USA Cellu-Cushion™ 8lb 3/16" PE outer rail skins. Stiff and strong, Brian hand laminates the rail strips then accurately trims them flush, perfectly in-line with the chine and slick angles to form precise edges. Todd then hand seals the open cells to give each custom that smooth brand new one of a kind Vortex Custom board. We stock a wide range of colors for both decks and rails and will be introducing special runs of custom colors for 2006. Colors change periodically and are subject to availability.