Okidoki, as u can see the corecell has been vacuumed on and smoothed out taking care not to over shape and generally keep things as close to the original as possible. Now thats all done i flip it over and prepare the bottom as i did the top. Next comes the glass, yay!

Had some small voids to fill after grinding it back
so what better way than with expanding poly foam, this stuff does work great u know. After this has set up hard i cut it off and smooth out the whole thing, if there are any pot holes the foam didnt get, it will get filled with a mix of epoxy and west filler then smoothed out again all to ensure the board is as level and straight as possible, believe me it isnt fun trying to get things smooth and level if you dont get these parts right come time to fair and prime.

I have been busy doing lots of work on the board and others and have been lazy with the updates (sorry) but im back with more so lets get into it aye.

Since the last post we have glassed the new nose piece and vacuumed on repairs for numerous damages on the bottom. Check the photo of the repair by the fins, this one had melted a huge amount of the EPS foam, so i had to cut it all out and glue in a new piece of foam. This one was done by mixing up some epoxy and west filler to create a toothpaste sorta putty. Then we applied it to the side that was going to front the old lamination and inserted it into place. It went in nice and snug so we didnt need much polyurethane foam to fill up the edges. It was then faired into the rest of the board, edges beveled and all vacuumed up!

Ill leave this part here and post my next one seperate.

Well welcome back, here we go with what i've done so far....
As you can see i've beveled the top of the board and filled the sub structure as necessary, the inner laminations all seem to have alot of delamination which i suppose is not surprising considering the amount of epoxy on them and the fact that with heating and cooling of the board over the last couple of years it has caused the board to expand and compress(this is why epoxy boards shuld have breathers).

Anyways i also marked out the nose section and ground out the previous repair and as before found some not so surprising disapearance of the inner foam! oh well may as well start again. I cut out the nose section and fitted some nice strong airex in its place, beveled the edges and shaped it. We could have tried to rebuild the old nose but considering the time it would take and the weight savings it would amount to decided on this much easier and still just as strong option.

Thats about it for tonight will post more soon.

Takayama Snap Repair

This is the current board in for repair at the moment, a 9'1 Donald Takayama. Now i Have to say they don't come much worse than this. It has had a number of repairs done but the person who has done these has used polyester resin which has caused large cavities in the EPS around the nose and middle section. The cavity in the middle was the cause of the cause of the boards failure due to its structural discontinuity.