Hey, thanks so much Clarece. That's a great tip - they have exactly what we want:
www.windance.com/True-Ames-Slalom-Pointer-34cm/6508/We've put Bic boards through a lot of hard work at times, with my 90-odd kg and really loaded up hard using a 35cm fin, and have never seen any weakening of the US box. I did have it happen in other boards, but not yet in a Bic. (this is harking back to 25 years ago) Maybe it's just luck, or maybe Bic reinforced the box pretty well? But considering that my wife and I are comfortable on the boards and they are so cheap anyway, I'm happy to persevere with US box fins for a while if I can get them. I actually have a CNC router and was thinking of making a mould or even direct cutting fins from f/glass block. But the Windance ones would be a better idea.
And if we do tear the fin box out, I could even have a go at retrofitting Powerboxes or Tuttle boxes (we have 3 Bic boards!).
I will inevitably upgrade to a modern slalom/ freeride board (might be harder to convince Janet ... she just loves the Metal Rock), but at the moment we're happy trying to learn to gybe and get general fitness and skills back on these old boards. I asked Simon at Board Crazy what sort of modern board he'd recommend, which had some of the attributes of the Astro Rock/ Metal Rock but in a more modern style and just off the cuff he recommended a Naish GT.