I've just finished building a Moonboard in the back garden and thought I'd put up a few photos/lessons learned in case anyone would find it of use.
Photos of the build https://imgur.com/a/kNXJp
Materials/Cost
Moonboard Holds (School Holds, Set A and Set B) £460
Moonboard LED Kit £500
Marine Ply (3 x 12mm sheets 2.4 x 1.2m) £180
Treated Timber (Posts and Framing) £225
Screw-in T-Nuts and Bolts £120
Fixings £50
Concrete £80
Corrugated roof sheets £75
Paint £110
Crash Mats (awaiting delivery) £600
The Build
1. I started by excavating holes for the posts that formed the base of the wall and the full height vertical posts, I bought a trench shovel which saved a lot of work – highly recommended if you’re digging into a flint bed! I then cut the base posts to size (with 40 degree angled tops so the base of the main frame could be fixed) and treated all cut ends and collars with bitumen paint.
2. Next up I used postcrete to set all of the posts in place – holes were 18” – 24” deep so it took between 2 and 3 bags per hole.
3. Built the frame with 4” x 2” treated timbers made up of 4 vertical pieces (3.6m) fixed to head and sole plates and noggins in between at 1.2m spacing so the plywood panels could be fixed. Once to the correct angle I used M12 exterior coach bolts to fix to the posts and screwed fixings into the base posts.
[Measure twice cut once] - My head plate ended up being right where my top row of T-Nuts were so I've had to move the top row up by about 30mm. At least it gives me an excuse when I keep dropping the last move!
4. After drilling 400 holes and fixing 200 screw-in T-Nuts into the plywood panels, they were prepared and painted with primer/undercoat/satin. I then fixed them to the frame, first two went in ok but my steps collapsed as I was trying to get the top board in place and I nearly lost a finger! I ended up drafting in some help from my other half and used an old rope to make a pulley to get it in to place.
5. Next up was a final paint job then the painstaking task of fitting the LEDs. They're all daisy chained so make sure to be careful when fitting. I wasn’t. I got to the end with a couple spare and realised I’d missed a bulb from A4 so had to take 196 LEDs out and start again!
6. Then came the fun part (marginally less tedious than fitting the LEDs) of installing the holds – I found a few of the T-Nuts to be threaded so I had to replace them. I’m glad I decided to do this stage before putting the roof sheets on.
7. Final step was to install the corrugated roof sheets and ridge pieces – a month on and it all appears to still be water tight which I’m relieved about. I’ve ordered 2 crash mats (2.4 x 1.4m x 300mm) which I’m waiting on delivery – the mattress and old sofa pads have been ok to start with but are a broken ankle waiting to happen.
I knew the grades were stiff but my fingers are slowly getting used to it, I’ve been using it 3 or 4 times a week for the past few weeks and can already feel areas that I’m improving. I’ve added some warm up jugs and once the mats arrive I can see me getting plenty of use out of it and hopefully seeing some longer term improvement.
Overall, I really enjoyed the build and am enjoying the board even more than I thought I would. The App and LEDs add an extra level of interest, being able to set problems for others and working through the benchmark problems will hopefully keep the training interesting. Highly recommend a home build and although not cheap it’s definitely more viable than the £8k for the freestanding board from Moonboard.