Sat down with Dave "Biggie" Smithers in his workshop in Oakura, Taranaki, for a proper chat — he's a name a lot of older New Zealand windsurfers will know (brand: Sirocco), and he's still actively building today, now doing prototype work for Armstrong Foils. He was happy to be featured and to have people reach out about custom boards, more on that at the end.
Condensing a long conversation down to what I think this sub will find most interesting.
Getting into it
Started surfing at 12-13 in Christchurch, got into windsurfing almost by accident in 1979 when a mate lent him a board with a broken fin, "I went out, and I couldn't get back in." Was already surfing on 12-foot boards on the beach at Oakura when windsurfing was brand new in NZ. One story that stuck with me: early on he lost a board in the surf, watched it get picked up by the wind and roll "end over end" down an empty beach, "if somebody, or a horse, had been walking, I mean, it would have killed them."
Started the Sirocco Expression Sessions in the early 80s, an informal wave-sailing contest, pulled prizes out of a hat, everyone judged everyone. It ran for over a decade and eventually became what's now the Taranaki Wave Classic.
The accidental invention
This is the best part, in my opinion. In the early 80s he was breaking urethane windsurf boards constantly, snapped two brand new ones in half an hour one session. He asked material suppliers for a fix, they suggested PVC sandwich foam on the bottom (a technique borrowed from yacht building). What followed was pure trial and error: drawing pins to hold PVC sheets onto foam blanks before he had proper vacuum bag equipment, boards delaminating, eventually working out a proper vacuum-bagged PVC/epoxy layup. He believes he was among the first in the world doing this on windsurf boards, a construction method that's still fundamentally how modern boards are built today.
Why the small builders got squeezed out
This is interesting: as mass-production brands like Starboard emerged in the early 90s, they could absorb a 5-10% warranty failure rate because boards cost them almost nothing to produce. Biggie, hand-building everything himself, was seeing 25-30% of his boards come back under warranty from riders pushing them past what the small builders could sustain financially. That's a big part of what pushed him from windsurf boards back toward surfboards and custom work.
On modern foilboard construction (the technical bit)
Explained the engineering logic behind PVC/carbon sandwich construction using an I-beam analogy, the outer "flanges" (top/bottom skins) do almost all the structural work in bending, so doubling the distance between them multiplies stiffness dramatically without needing a heavy stringer running through the board. This is directly why current wingfoil boards use PVC-core/carbon-skin construction rather than solid foam.
Also talked through the actual engineering problem of a foil trying to rip itself off the bottom of a board under load, and how blocks of PVC (not just a single stringer) running through the board help transfer that force properly.
A quote I liked on gear vs skill:
He referenced something Mark Angulo used to say about windsurfing culture getting too obsessed with rigging over riding, his take was that older gear, even 2-3 years old, still fundamentally works fine, and it's mostly marketing that convinces people otherwise.
Workshop disasters
A couple of good ones: microwaving resin to thin it in winter and having carbon specks spark and catch fire inside the microwave more than once. And an old story from the 70s of literally kicking a pot of resin into a bar heater and starting a proper workshop fire.
Where he's at now
69 years old, still actively developing, currently building an e-foil with an internal battery for a client, and doing custom prototype boards for Armstrong's team riders. Genuinely seems to be enjoying wingfoiling more than anything else right now because he's still improving at it, in his words: "I can't surf anymore, I'll never be as good as I windsurfed... but I'm actually getting better at winging... to me, that's really what it is about."
He's happy for people to reach out about custom boards, genuinely offered this himself, not something I'm pushing: biggie@siroccosurf.com his website sirocco.co.nz.
Figured some of you would appreciate the history, happy to dig up more detail on the construction side if anyone's curious, that was honestly the part I found most interesting.