CRACKED

BOARD?

OH NO.

L E T ’ S G

E T CR A C K I N

G !

FANATIC FREEWAVE ’05 NOSE-JOB

Stefan Debattista & Matthew Babcockstefan@8am.com.mt

SHOPPING LISTXPS FOAM – WE USED 32KG/M3 – IN MALTA AVAILABLE FROM

VIBRO BLOCKS (VASSALLO) IN ZEBBUG OPPOSITE TOYOTAEPOXY RESINKEVLAR / CARBON SHEETSSEE THROUGH PLASTICGLOVESPAINTBRUSHPERMANENT MARKERGRINDER + SANDPAPER (100/300/500)PEEL PLYSAW (LEATHERWOMAN SAW WORKS FINE)

WHAT’S THE DAMAGE?

RAIL CRACKED FROM TOP TO BOTTOMPREVIOUS REPAIR BROKEN

CLOSER LOOK AT THE DAMAGE

SLOWLY GRIND AWAY TOP LAYERS ON TOP OF ALL DAMAGED AREA

FOAM UNDER PREVIOUS FIX ALL CRACKED

TAKE IT ALL OFF

CUT AWAY THE BOARD ONLY LEAVING GOOD FOAM & CUT A PIECE OF XPS FOAM TO FIT THE CUTOUT

WE DECIDED ON A TRIANGLE AS THIS MEANT WE WOULD HAVE TO TAKE OFF THE LEAST AMOUNT OF ORIGINAL AREA

GLUE THE XPS FOAM ON

WE USED AN ADHESIVE WHICH TOOK A WHILE TO DRY – WE RECKON SHOULD HAVE USED EPOXY

FOAM REACTS TO POLYESTER – MAKE SURE TO ONLY USE EPOXY RESIN (GLUE). DO NOT USE ANYTHING ELSE LIKE POLYESTER RESIN ACETONE OR ANY OTHER CHEMICAL AS THEY CAN MELT THE FOAM INSIDE THE BOARD

STICK ON, PRESS DOWN AND SUPPORT

SHAPING

USE A SAW TO CUT AWAY THE CHUNKY PIECES, AND SANDPAPER TO GE THE SHAPE OF THE BOARD.

PREPARE THE OVERLAP

SAND AWAY ABOUT 2CM OF THE GOOD PAINT ON THE PERIMETER OF THE REPAIR JOB. THIS WILL BE USED TO OVERLAP THE NEW REPAIR.

USE COARSE SANDPAPER LAST TO SCRATCH THE KEVLAR

MAKE A TEMPLATE FOR CARBON + KEVLAR

MAKE A TEMPLATE OF THE AREA TO BE COVERED IN KEVLAR + CARBON. WE DECIDED TO USE A LAYER OF KEVLAR ONLY ON THE TOP + RAIL AS THE BOTTOM OF THE BOARD IS SO THIN. WE LABELLED THE TEMPLATE WITH TOP AND BOTTOM WHICH MADE IT EASIER TO PUT THE KEVLAR + CARBON BACK THE RIGHT WAY STRAIGHT AWAY (AFTER PRIMING IT)

CUT OUT CARBON + KEVLAR

CUT OUT THE CARBON AND KEVLAR TO MATCK YOUR TEMPLATE

PRIME THE KEVLAR + CARBONUSE JUST ENOUGH EPOXY TO WET THE CLOTH

PAINT SOME ONTO THE BOARD, AND THEN PLACE THE CLOTHS ONTO A WORKTOP WITH A PIECE OF PLASTIC UNDERNEATH. APPLY THE RESIN TO THE CARBON + KEVLAR ON THE WORKBENCH WITH A PAINTBRUSH. BEFORE YOU PICK UP FIGURE OUT HOW IT FITS ON THE BOARD (CHECK YOUR TOP AND BOTTOM MARKINGS ON THE TEMPLATE) AND THEN PLACE ONTO BOARD

TREAT IT LIKE A CAKE. THE LESS YOU PLAY WITH IT THE BETTER

JUST PLACE THE CLOTH ONTO THE BOARD, PRESS IT DOWN A BIT – THEN MOVE TO NEXT STEP

COVER WET CLOTH IN PEEL PLY

COVER THE REPAIR IN PEEL PLY AND THEN USE A BRUSH TO PRESS DOWN ON THE CLOTHS TRYING TO KEEP IT ALL AS FLAT AS POSSIBLE.

GET IT HOT WITH A HAIRDRYER (1/2 HR)

WAIT AS LONG AS POSSIBLE (4 HRS MIN, IDEALLY 15 HRS+) AND PEEL OFF THE PEEL PLY

AND THEN SAND AND FINISH