Does anyone got any ideas about where to get small amounts of EPS foam of sufficient quality for board repairs? Are there any readily available domestic items that have good enough foam like eskies and so on?

I find 2 pack polyurethane foam (better version of Bunnings expanding foam) works better than gluing in styro, as it fills all the tiny gaps and really infuses through the foam, gluing up cracks as it goes.
Shaping a bit of styro to fit a hole is annoying. Erathane GP330 usually, 2L kits lasts me for years

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Mark _australia said..
I find 2 pack polyurethane foam (better version of Bunnings expanding foam) works better than gluing in styro, as it fills all the tiny gaps and really infuses through the foam, gluing up cracks as it goes.
Shaping a bit of styro to fit a hole is annoying. Erathane GP330 usually, 2L kits lasts me for years

Yes. Its a good plan, but all up it will cost 60 dollars for me to lay my hands on some here. Still, as you say it will get into all those nooks and crannies....

Isn't it from over there?

I got some 2 pack polyurethane foam from local fiberglass repair shop who had it in bulk
got two jam jars filled for $10 and works great.

Oh yeah forgot to mention also, if you want to go down that path, best source of dense stuff about H or VH grade is cray pot / crab net floats - but not used unless you want to slice n dry well

Or for big chunks like a whole-removed-nose job, "Knauf" board from bunnings is a XPS that is similar density to surfboard (PU) core foam. It works and is cheap but it can outgas causing delam, so after cutting it needs some time in the sun to let it fart away for a bit.

try ordering from polyfoam they have an outlet in Qld and usually have left over blocks from cutting as mark said use VH

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Mark _australia said..
Oh yeah forgot to mention also, if you want to go down that path, best source of dense stuff about H or VH grade is cray pot / crab net floats - but not used unless you want to slice n dry well

Or for big chunks like a whole-removed-nose job, "Knauf" board from bunnings is a XPS that is similar density to surfboard (PU) core foam. It works and is cheap but it can outgas causing delam, so after cutting it needs some time in the sun to let it fart away for a bit.

Epoxy dreams off XPS...it off-gassed when shaped. Starboard learned a hard lesson a while ago...then used it again..it coincided with a global shortage of the German made HD pvc foam so it was probably due to necessity rather than stupidity. JP used it too. It's poo poo

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Mark _australia said..
Oh yeah forgot to mention also, if you want to go down that path, best source of dense stuff about H or VH grade is cray pot / crab net floats - but not used unless you want to slice n dry well

Or for big chunks like a whole-removed-nose job, "Knauf" board from bunnings is a XPS that is similar density to surfboard (PU) core foam. It works and is cheap but it can outgas causing delam, so after cutting it needs some time in the sun to let it fart away for a bit.

Epoxy dreams off XPS...it off-gassed when shaped. Starboard learned a hard lesson a while ago...then used it again..it coincided with a global shortage of the German made HD pvc foam so it was probably due to necessity rather than stupidity. JP used it too. It's poo poo

^^^ not if you allow it to offgas under heat after shaping.
Lots of blueboardXPS surfboards out there are just fine.
The problem is cheapo product and rushing, then expecting that the gas voids just under the exterior won't offgass later. well they do the fist time it gets hot...

If is old foam ,then shaped, then allowed to sit in the sun for a bit then it has done all the outgassing it is ever going to do and its fine. Mass production at Cobra is quite the opposite...

^^^^Delams;p

The foam used in those surf boards has a patented treatment as I understand. A micro-perforation process.

i won't trust it on my customers jobs. Quick n dirty diy I'm sure it's fine