On this one the styro has compressed a bit and also has a crack across the damaged area. I was planning to rout down into the styro 6mm and glue in a 6mm piece of HD foam, then a thin layer of glass then another 6mm layer of HD foam and then the external skin.
Or should I try to get hold of some styro for the first layer?
Piece of stiff plasic over the hole in the styro.
Inject expanding foam (proper 2pack not bunnings crap)
Then it will
- fill all the cracks and glue the styro back together (over quite some distance internally, as you are stopping it from escaping too much)
- fill the styro depression up to the right level
Looking at these sort of repairs now, I wonder what I would do with that sort of damage.
I mean, I like cutting out finboxes and adding new ones, and adding new footstrap inserts. I have enough 'extra solid' boards to show for it, but with damage like that, I can't help but feel I would have just injected a little bit of resin into the cracks, plastered a bit of q-cell and epoxy mix into it, and maybe add a layer of glass or two over the top once it has hardened and been sanded back.
Are we getting too concerned about perfect repairs? It is a genuine question as I never seem to sell boards on, so I don't really see how cheap repairs compare against doing it perfect after it has been used for a while.
One of my first repairs was to a 5 cent hole in a carbon board where I just filled it with epoxy and filler, and it is still fine after a few years.
That looks nasty!! About 20 tubes of Marine epoxy putty should fix it though
P.S. Mine's fiber glassed, painted and ready for tomorrow's NE'r.
Used the router to cut out the bulk of the damaged styro and chop down the HD foam to just shave the glass layer in between. Also used the router to take off the surrounding paint and expose the glass beneath ready to overlap the new outer skin on to.
All ready for a big glue up tomorrow followed by routing down the big plug to the level of the EPS core. I'm lucky that this part of the board is very flat - makes it easy to use the router.
That looks like a bit of an over kill for a non stress part of the board.
Sand, lightweight Q-cell mix, glass, sand, Go sailing, drink beer.. would have been the better option.
Looking good Ian - there's nothing wrong with doing a great repair job, if you have the time knock yourself out !
Some more pics showing the styro core fully restored, glass cut out ready to go under the pvc foam and the pvc foam cut to shape. Another glue up tommoz.