Getting back in shape

A little more than a year ago, the surfing industry was in an uproar and fearing an uncertain future when Clark Foam, the major supplier of polyurethane blanks used for surfboards, closed unexpectedly in December 2005.

But other foam manufacturers have stepped up to the plate, either ramping up production or starting new companies to ensure that local shapers can still produce their boards.

The competition in the marketplace has also proved healthy for the surfing industry, making foam companies produce higher-quality foam.

Costa Mesa-based shaper Dan Taylor said Clark’s closure was a blow to the industry but that he and other local shapers have fared well with the emergence of other foam makers.

When Clark shut down, Taylor had about 500 Clark blanks in his shop and said he was “quite lucky with that.” But, with the supply dwindling, Taylor soon turned to epoxy blanks, a newer material shapers and surfers are experimenting with.

Although polyurethane blanks still seem to be the most popular, the idea that Clark’s closure meant the end of foam blanks forced shapers to look to other materials — some of which are hotly contested among the surfing community.

Epoxy resin is one material shapers and surfers have been experimenting with, although some say it can be difficult to work with and repair and that it isn’t flexible enough in the water.

“We’re not entirely sold on it. We think there’s a lot more that needs to be learned in that area,” said Newport Beach-based Russell Surfboards spokesman Tim Manno.

Gordon “Grubby” Clark closed his Laguna Niguel-based company suddenly on Dec. 5, 2005, sending out letters to shapers saying the closure would be effective immediately.

Clark basically had the monopoly on the market in the United States — and arguably around the world — with some competition in Australia and South Africa.

A new foam manufacturer called US Blanks, started by former Clark Foam workers, has become one of the favorites among some local shapers and companies, including Taylor and Russell Surfboards.

“I just started picking and choosing” from different foam manufacturers entering the marketplace, Taylor said, noting that US Blanks has been putting out some quality blanks.

“We didn’t know who was going to fill the void with Clark closing down,” Manno said. “Competition is improving, but we haven’t yet seen the full potential.”

Firewire Surfboards, which make an epoxy-composite board with balsa rails, has become increasingly popular at Costa Mesa’s Surfside Sports, owner Paul Burnett said.

Clark Foam’s closure “opened people’s minds to the possibility of not just substituting other materials for boards, but a little more willingness to take a look at changes totally in materials as well,” Burnett said.

With a year of reflection behind them, people in the industry have begun to realize that maybe the status quo wasn’t good for the business.

“When Clark was in business, no one spoke ill of it,” Burnett said. “Now they talk about the blanks and say there were problems, soft spots and other various things, and people are claiming other foam products … are better-quality blanks than they used to be able to get. But before they didn’t say anything because they didn’t want to get cut off.”

But most shapers do acknowledge missing the regularity of Clark and said they miss placing those orders.

One of the advantages of Clark Foam, aside from Clark’s seemingly top-secret formulas for his foam and his commitment to fixing glitches, was the variety of blanks he provided to shapers.

“I respect the guy totally. A lot of people are throwing dirt around…. It ruined a lot of livelihoods, but he knew what he was doing — he’s a smart businessman,” Taylor said. “His foam was good, but what’s out now is getting better.”

As foam manufacturers work out the glitches — Manno said many companies were just trying to produce too much too fast; Taylor said some of the companies were taking advantage of the situation — shapers are seeing the product getting better.

“I think we’ve taken a step back, but in the long run we’re going to learn more and definitely take a lot of solid steps forward,” Manno said. “It’s just hard to say how long that timeframe is.”

The consensus among shapers and surf shops seems to be to think positively, with competition hopefully spawning new innovations, better foam and better prices.

Taylor returned this week from a trade show and was happy with what he saw and the feedback he received.

“It looked pretty good for me. It wasn’t the same, but hopefully this year will be better,” Taylor said. “Anything will be better than last year.”