Shaping and Cutting Profile

Decide on the shape and make a template out of card etc.
Cover both sides of the deck with wide masking tape.
Transfer the shape on to the base of the deck
Draw  centre lines along and across the deck
Mark centres for the trucks, foot straps and grab handle etc.

Use well fitting mask, eye protection, ear protection and gloves.        

Clamp the deck firmly overhanging a bench.
Check cutting clearance below the deck. 

Use HSS jigsaw blade for metal cut along the profile using
steady firm pressure at slow speed.
 
  
   Using bursts helps to keep the heat down.
   Replace blade often as it will blunt after about 40 cm

   VIDEO showing the cutting process 1.3 Mbytes DOWNLOAD

  
   You will need 4-6 blades per deck.

    
   Finished deck cut but still need edges smoothed
   Use coarse down to 1500 grit wet & dry.