Updated: Dec 7, 2018
You've been there; you come up from the water after you botch a turn or have a close-call with a buddy and the panic sets in. Even more common, you're pulling a favorite board out of your car or shed and the distinct "clunk" and "crack" sound jolts you out of your pre-surf stoke. That sinking feeling you get in your stomach when your quiver takes some damage is the worst, but no more! Keep reading to learn how to repair your boards like a pro and to find out how you don't have to do it alone.
The most important step of a good repair is assessing the damage and determining the most effective approach to making it right. Unfortunately, this requires making things a little worse in order to get a better final result. Forget everything your mom ever told you about not picking scabs and get in there.
- Use a razor-knife and/or sandpaper to remove damaged fiberglass and/or foam. At this stage, try not to cause new damage to undamaged areas, but open up the ding by removing damaged material until you get to un-cracked glass and/or smooth foam.
You may just have a crack in your top smooth "hot-coat" of resin, in which case you should just sand the area down enough to remove that crack/chip and then you can skip to the "Hot-Coat" step.
If it's a noticeable ding, you probably have lamination damage, meaning the main layer of fiberglass over the foam is compromised. If, after removing the damaged fiberglass, the foam is undamaged (which isn't super-likely!) you can skip to the "Lamination Prep" step.
Most semi-serious dings include some foam damage. Remove damaged fiberglass and sand down the underlying foam until you get to nice, white, smooth, foam. Then move to the next step.
- Blow off any dust from the previous step and, if necessary, use masking tape to build up a reservoir that will form the liquid filler mixture to a shape as close to the finished shape of the board as possible.
- Mix up your filler mixture using laminating resin and Q-cell or micro-balloons (for poly boards) or epoxy part A and Q-cell or micro-balloons (for epoxy boards). This mixture should be about the consistency of Elmer's glue (if using epoxy, your mixture will be thicker than glue until you add your part B catalyst, but try to achieve that consistency before applying the mixture to the board).
- If you wish to color-match your repair to a colored board, add resin-tint or pigment to your filler mixture to achieve the desired color. Just a little goes a long way and it's fine to mix multiple colors to get the color you're after. No secrets to this, but I recommend Googling the color-wheel or calling your elementary school art-teacher if you can't get it quite right.
- Add catalyst to your mixture and mix thoroughly to ensure consistent kick.
- Pour filler into your damaged area little by little to minimize bubbles. You can use your mixing stick to poke at the filler to try and work-out any trapped air.
- Allow mixture to cure and become solid, but try to catch it before it gets totally hard.
- Remove tape and use a razor to trim obvious excess away from damaged area to reduce necessary sanding in next step.
- Allow for full cure.
- Use low-grit sand paper by hand or with sander to shape foam filler to desired shape and to remove enough thickness of “good glass” from about 1/2" surrounding the ding to make room for new cloth. You should be able to see the exposed weave of the good glass that you are sanding away.
^^This step of sanding down good glass from the surrounding area is the most commonly overlooked step and results in either a lump repair, raised above the rest of the board, or a repair that ends up being sanded away in the final steps of trying the finish-sand the board.
- Hand-sand the area to remove any hard edges left behind by the sander.
- Blow off excess dust.
- Touch-up any missing/damaged paint or pin-lines.
- Tape-off area around ding to prevent flow of excess resin onto undamaged areas in next step.
- Cut patch of fiberglass cloth to match size and shape of damaged area. You can use multiple layers of cloth if necessary depending on depth of damage.
- Mix laminating resin: Lam resin + catalyst for poly, Part A + Part B for epoxy.
- Use mixing stick to apply resin to cloth and wet-out the cloth entirely, but pay close attention to use as little resin as possible to do this to achieve strongest and smoothest lamination.
- Allow to cure.
- Mix hot-coat resin: Lam resin + surfacing agent + catalyst for poly, Part A + Part B + Additive F (if necessary) for epoxy.
- Apply to whole damaged area with mixing stick or cheap paint brush. Try to achieve a smooth layer of hot-coat resin that is thick enough to fill the texture of exposed cloth, but thin enough to not build-up or drip.