The Workshop
Where CNC precision meets hand-crafted tradition. São Vicente, Madeira.
Fajã Surf Labs was born because Madeira needed it. World-class waves, a deep surf culture, an island shaped by the ocean — but nowhere here building boards to the standard those waves deserve. So we built it.
We set up our workshop in São Vicente, on Madeira's rugged north coast. Shipping containers converted into a shaping bay, a glassing room, and a finishing area. A CNC machine handles the heavy cutting with sub-millimeter precision. Our shapers handle everything else.
Every board is shaped to order. No stock boards, no compromises. You tell us what you want, and we build exactly that. The CNC gets us 95% of the way. The last 5% — the rails, the foil, the feel — that's done by hand.
We glass on-site, cure properly (no rushing), and finish to a standard we're proud of. When you pick up your board, it's ready to paddle out.
CNC Machine
Shaping Bay
Glassing Room
Finished BoardFrom blank to surf-ready.
Design
You configure your board online. We translate your specs into a CNC-ready 3D model.
CNC Shaping
Our machine cuts a polyurethane blank to within ±0.5mm of the final shape. Precision that hand shaping alone cannot match.
Hand Finishing
Our shapers refine the rails, concaves, and foil by hand. This is where the board gets its soul.
Glassing
Fiberglass and resin are applied by hand using your chosen schedule. This gives the board its strength and flex.
Curing
48 hours of controlled curing ensures the resin bonds fully. No shortcuts.
Sanding & Finish
Sanded smooth, polished, and inspected. Fin boxes installed. Leash plug set. Ready to ride.
Services
Ding Repair
Cracked rail, snapped nose, pressure dings, or a leaking fin box — bring it to the lab. We repair boards to ride-ready condition with the same glassing and finishing we put into every custom build. Fast turnaround, done properly.
For Shapers
Rent the Bay
Passing through Madeira and need somewhere to shape? Rent our fully-equipped bay by the day or week — CNC machine, shaping stands and lighting, a glassing room, and all the tools. Blanks and materials available on request. Just bring your hands.
Learn
Shaping Classes
Shape your own board alongside our team. From reading a blank to foiling rails, glassing and finishing — a hands-on session where you leave with a board you built yourself and the skills to do it again. For all levels, no experience needed.
See for yourself.
Visit our workshop in São Vicente when you pick up your board. We love showing people around.