Surfboard Repair 101
You did it, you broke it didn't you? You got a ding in your board and now, you need to fix it. So, you're asking yourself, how do I repair a surfboard - my board!
If you have sustained a major ding, like a board broken into two pieces, delaminating or peeling larger than the size of a CD, take it to a professional
Before you try to fix anything on your surfboard, you need to know what kind of board you have. Not a Channel Islands, Lost or JS, but what manufacturing materials. What is your board made of? Is it polyester (PU) or epoxy? If you don't know, find out. Using the wrong materials to fix your surfboard can turn it into a puddle of sticky goo and that's no fun at all. Use the right materials and you'll avoid potentially ruining your surfboard.
Do your repairs in the late afternoon. Surfboards expand and contract with the temperature. The primary ingredient in a surfboard is air. Per volume at sea level, your surfboard is mostly just air. Air expands and contracts quickly and so does your surfboard. If it expands enough, it rips the glass from the deck and causes delamination. Many newer boards have plugs just for gas expansion. For this reason, you should do your repair in the evening hours. The air inside won't be expanding and pop out your repair.
Emergency Repairs: I know you're not always going to wait to get your ding fixed. The waves are all time and it's just a small ding. I know, I've been there and done that. Here are a few things to help minimize damage since you can't get your board repaired right away.
- DO NOT use duct tape. Duct tape is porous and leaves a sticky-filmy residue on the surfboard. It's hard to clean and it's going to let in water anyway.
- DO NOT use wax. I know, it seems like cramming a piece of wax into the hole will help, but it won't and it's going to make future repairs more difficult and less likely to adhere. I've used wax before myself, I know how tempting it can be. You're going to have to cut out a larger piece of foam when you repair it if you used wax. Resin doesn't adhere to wax.
- DO NOT use super glue. This is going to really destroy the foam on an EPS and probably doesn't do much good for a polyester board either. I've used wax, but thankfully, I saw what super glue does and have never been tempted.
- DO USE epoxy puddy. For epoxy boards. It's a two part epoxy product (usually green with a white core) and it's inexpensive. Mix it, form it, and shove it into the ding. It dries strong, fast(ish) and water tight. Put a piece of this into your ding and cover it with a sticker and you have the best temporary repair there is.
- DO USE stickers. Yes, those plastic surf stickers you have all around your car, room and office are actually pretty good for temporary repairs. A lot of boardshorts and other surf gear come with a little pack of sticker designed for ding covering. They really work and keep the water out, if you got a good seal. Get a really good seal and you can wait a few days for the real repair.
Epoxy board need epoxy repairs. The resins, catalysts and thinners used must be epoxy friendly. Epoxy surfboards are made with styrene foams, the same type of foam so popular with coffee cups and cheap coolers. If you put a Polyester or Vinyl ester product on a styrene product, it melts. It may be a fast reaction and it may be a slow reaction. Don't "test" a chemical and expect it to be OK, because you're not seeing a reaction. Some of the reactions are slow, but infinite. Be very careful what you use on your epoxy surfboard. If you're not sure, don't use it. Epoxy putty, sometimes called "ding stick", works very well for filling small holes and cracks in your board. It's also very inexpensive, easy to work with and forms a good bond with your board, if you prepare the surface properly. You can keep a tube in your vehicle for a long time and it should be good to go when you need it. I have one in my board bag. For clear finishes, you will need an epoxy resin. You can order these online or through your local surf shop. Most shops don't carry the epoxy liquid resins, but as more and more boards are epoxy, this may change. Use the same cloth as PU board repair.
Polyester board repair is nice, because there are several methods and some are fast and easy. You can also use the same resins and catalysts that you will find at a boating and marine store, but be warned, these resins usually dry yellowish or with a tinge of blue. Using resin specifically made for surfboards will result in a clearer finish and a more professional looking repair. You can buy surfboard resin at your local surf shop or at a few dealers online. A quart should last you a long, long time. Fiberglass cloth and catalysts can be purchased in the same location. Sun Cure or Suncure is a really 'neat' product for surfboard repairs and serves a good need.
SunCure warning: The catalyst is solar radiation, so there's no mixing needed. However, Suncure suffer's in that it has to be used in sunlight and direct sunlight will cause your board to warm, expand and potentially compromise the repair.
Preparation for Repair: The Golden Rules
Follow the directions
Read the directions of the repair material you are using. Then, read them again. You're going to be working with some powerful chemicals. Polyester surfboard repair chemicals can be very dangerous, explosive and flammable. Treat them with extreme caution and don't ever leave them in direct sunlight. Polyester catalyst, in particular, is the nastiest of the chemicals you're going to be using. It's sold in small one ounce containers, which for some reason, are shaped like a Visine bottle. You do not want that stuff in your eye.
Remember: Once you start, don't stop
Do not walk away from your resins. This is rule 1. You'll mix the resins, have everything done and it's looking like nothing is really happening. Don't walk away! Once the reactions start to occur and the resins become workable, the reactions can occur VERY quickly and remember, these are one way reactions. Once that resin hardens, the only way to remove it is sanding. Your patience will be tested. Generally, the warmer it is, the faster the reaction. Follow the
Dry the surfboard.
I don't just mean take a towel and dry it off, I mean let the board drain. Before making a permanent repair, you want to make sure all the moisture is out of the board. Hang the board so the ding is the lowest spot on the board and let gravity do its thing. The water will drain out, but it can take a long time. If you're in a very humid environment, your board can actually absorb moisture from the air, so do you repairs and prep in as dry an area as possible. There are a few methods to speed up the process such as vacuum bagging. Vacuum bagging creates a vacuum in the board and helps pull out the water. I've never used this method, but I hear it works miracles and can also be used in advanced repair techniques.
Clean the wound.
Your doctor wouldn't stitch you up without cleaning out the wound and the same is true for surfboard repair. Remove all loose debris and materials. If you've crushed a rail, cut away the area that was crushed including the inside "good foam". You want your repair to adhere to a good surface and crushed foam is not a good surface. It's hard to take a knife and cut away at your already damaged board, but repairs built on the proper foundation will last.
Assemble the materials and safety equipment
Get the proper resins, catalysts, fiberglass cloth, mixing cups, masking tape, scissors, utility knife, saw, disposable brushes and whatever else you may need. I know a lot of people want to wear glove and they're probably needed, but get the wrong gloves, for the resin you're using, and you can melt the gloves to your skin - ouch. Ask which kind of glove you need for the type of materials you're using. Safety glasses are mandatory. You're going to have little pieces of shattered fiberglass and some really nasty sticky chemicals once you begin working with the resins and catalyst. Safety glasses are not something you should skip. Get a mask.
Methyl ethyl ketone peroxide (MEKP) is some nasty stuff. Yes, I did mention this earlier and it's worth revisiting the subject. That picture on the side that shows someone's finger being dissolved, that could be your lungs. It's also explosive. Highly explosive. In its undiluted state, if you dropped it, it could potentially explode. Thankfully, the MEKP you're likely to see is diluted and much more stable. However, it's still a very volatile and dangerous chemical. Use per directions!
Prepare your materials
Get everything in one place. Once you start mixing resins and applying them to the surfboard you can't walk away to go find something you might have forgotten. You need everything within easy reach. If you need to use fiberglass cloth for your repair, cut it before you begin. What are you going to use to clean your tools and yourself? Have it ready and not behind a door knob.
Ask for help.
If you know someone who has repaired a surfboard, ask for their help and assistance. Try to watch someone make a repair and drink in everything you see. There's a lot more going on than you would think.
Now, go fix it!
Repairing your surfboard is part science and part art. The more you work with and understand the process, the more comfortable you will become and the better your results will be. Start slow and be patient.
Finding Professional Surfboard Repair
Weight and balance are critical components of surfboard repair. Professionals in the surfboard repair industry know how to keep the weight down, the strength up and still make it look good. Yes, there are dedicated professionals who repair surfboards. These people have perfected the art and science of surfboard repair.
High value collectable surfboards should always be shipped to a repair artist. These professionals understand both the science and the art of surfboard repair. They can make your surfboard look brand new. These people stand out in their field and are sought after for restorations and challenging projects. Their prices are generally very reasonable, but the shipping can be expensive. The Board Lady, located in California, can make miracles happen to damaged boards. She specializes is epoxy reconstruction and repair of surfboards, wind surfers and any project where the final result is museum quality.
Your local surf shop probably has an employee who does surfboard repairs. Surf shop repairs are usually very good to excellent. The turnaround is usually very fast, unless a big swell has sent in a lot of boards. They do good work and they're convenient. For most people, this is your best option for finding someone to repair your surfboard for you. You're at the beach anyway, why not just drop it off?
Friends are another great resource. Having an extra set of hands available and the eyes of experience will always help when you have questions about surfboard repairs.
It happens to everyone and to some, it happens way more often than others. Here are a few of the absolute basics you need to know and also some very advanced techniques for those in the know.
