Can anyone walk through printing or saving full size outline and profile templates from AKU?  I want to take the file to Kinkos and have it printed on one big sheet.  Thanks

Thanks but I'm not familiar with AutoCAD.  Does anyone know specifically how to save an AKU .BRD file so I can take it to Kinkos to be printed in full size. 

I know this is not the answer you are looking for.  But, since the template would eventually need to get transferred to Masonite, the full size print is not important.  Here is a low tech but systematic approach.

http://www.greenlightsurfsupply.com/templates.aspx

I could print a template on my plotter but I think I'd simply do it exactly as talldude just described. Old school is actually easier in this instance.

I design boards in shape 3D or Solid works to work out basic outline, profile and volumes. I import photos of boards into solid works to use as reality checks against my curves.
Then I do a dxf export of outline and profile. Open them in Adobe Illusrator. There are some free online programs that work similar to Illustrator.
In Illustrator, I redraw the lines and curves again, erasing all the dxf curves, to ensure there are no line segments buried in the dxf export.
I lay up the curves for templates on the 4x8 ft masonite. This requires that I split them in half to fit. Then I send those files to a furniture maker that has CnC router and he makes my templates in 3mm masonite.  the furniture maker is a colleague of mine at work ( we both work in design/development at Sony.)  he has a shop that he runs on the side, and gives me a bro- deal.

He keeps wanting to try to CnC the entire 3d shape, but I keep telling him that thats the fun part  to do by hand.

When I export the 3d files from solid works or Shape 3d, I then open those files in Illustrator. 
I have found that curves can be converted to line segments, which are not accurate.
Also, the curves are really messy, segmented and lots of control points. You can tell the math is getting corrupted. Which can cause problems in the CnC.

So I just use the imported dxf curves as guides and redraw them in illustrator.  Then I know they are clean.
At this point I have profile ( side view of rocker and deck) and outline ( top view) of entire board. This cannot be cut out of a 4x8 ft sheet of masonite.  so I create an artboard ( page size) that is 4x8 and place the template outlines on the artboard. The templates are too long, so the outline and profile curves have to be split in half lengthways to fit. I am arranging parts on the 4x8 masonite for the CnC machine.

Other way is to print out on many peices of paper,  tape together,  glue them to masonite and cut with jigsaw and then file or sand them down to line. Take a few days work. Totally do- able..I've done it back in pre CnC days,  actually pre computer days. I had bought templates for  5 m wood boat..that took 500 hrs to build...

Thanks!

My kids are proficient with illustrator but too impatient to teach me. I've watched them free-hand something, then scan, then open it up in illustrator. Then they trace over it like you do (for clarity - in another layer) and save that as their digital version of the artwork.

I didn't know that illustrator could output in a file format that could be read by a 2D CnC machine. That is awesome to know.

Interesting topic. Subscribed.