I regret to inform that the FKD up is totally rooted .
The FKD is fkd !
Cant be fixed .
Washed the sugar coat off and left it in the only warm sun for half hour . It blew up like a balloon . The whole top front half of the board , raised it 4 inches in the middle !!!
Something inside gassed up like crazy . Im thinking even if I replace the top front lam , will it do it again ?
It delaminated between the first layer of glass and the divinycell. Its where it didn't seem to stick well . The gas could have come from inside and gone through the first layer of glass , not sure ?
Was it the expand foam in a can that I used to glue the foam together ?
Also the divinycell that I used was much more crumbly and porous than the stuff I usually use and the lams didn't stick to it that good . That's not why it blew up but its just a thing I noticed as well.
So I'm not sure what happened and caused so much air or gas inside . I don't want this to happen again !
A $650 whoopsie 
After I finish sooking I will make another one . I will make it the same shape but I have to know what went wrong .
The green stuff on the left is what i usually use . Its denser and a smoother finish . The yellow stuff on the right , ( which i used this time ) , is very porous and crumbly .
Is this what other builders use or is this a crappier grade ?
oh, mate i'm sorry to see that happen to you.
is there a chance moisture in the eps caused the explosion.
Sometimes Huey see's something which is TO MUCH of a weapon and accordingly takes action.
Next time go the full camouflage graphics next time to hide the boards awesomeness.
Select to expand quoteGestalt said..
oh, mate i'm sorry to see that happen to you.
is there a chance moisture in the eps caused the explosion.
It could have been .
I think ill just pour resin over where I hacked and take it for a spin , without pads and make sure if it works before copying it again . Hope it doesn't snap !
Sorry to see that imax did you install a vent screw? I always wondered why they are necessary is this what they are designed to prevent ? Ive used the yellow one to reinforce a deck either side of mast track and centre board and had no problems with it. Im pretty sure the yellow one is what they make racing car panels from.
IT did have a vent but it was filled with foam and gripped over. That was the next job to drill that out .
Vent plugs are for that reason , but something went very wrong to have blown up that much in such a short time . It would have happened on the beach in 5 minutes . Huge amount of gas . Id estimate the volume of two blown up balloons . I was scared handling it , thought it could have blown up in my face .
I have no real idea , must have been some chemical reaction to the heat , or something.....???
Bummer mate!!!!! That's horrible.
There is a formula somewhere for expansion of air with increase in temp. A mate of mine was making a hollow board and was wondering if he needed a bung, the formula said not really.
Another mate of mine did a similar thing to you, joined styrene with expanding foam, so far his board hasn't blown up, but he was having a hell time during construction, with air bubbles coming through the epoxy.
bugger ....NEEDED a air vent .
HEY ,YOU COULD use that for a mould and make the FIRST air in side FKD ?
JUST AN IDEA . just go sailing and think about it .
I know the feeling. I crushed a SUP board in a vac bag. Expensive learning. I now have a gauge and valve.
Its all about experimenting and learning with home builds.
The expanding foam sounds like the most likely culprit. PU glue works well and doesn't gas anymore once its dry.
Select to expand quoteTardy said..
bugger ....NEEDED a air vent .
HEY ,YOU COULD use that for a mould and make the FIRST air in side FKD ?
JUST AN IDEA . just go sailing and think about it .
It was way more than a air vent thing . I would have needed ten of them . Were talking about the thing ballooning , I should have taken a pic before popping it but I wanted to see where it delaminated . It would have had to pull the sides in quite a bit to get that volume of gas inside .If it was the foam I might have injected resin under it to kind of save it , but it would have been ugly . I'm leaning towards the expanding foam glue . Its the only thing I've done different to my other boards .Possibly the contact glue I used to stick the divinycell down with . But ive done that on other boards . Possibly glassing over it the next day and it wasn't dry enough ??? I've also heard that you should leave the blank a couple days before glassing to let gas out , again ???
Next time ill leave the finished blank for a couple days in the sun before covering it . Again with the gluing of the divinycell core . Make sure there's no strange fumes inside .
Next time ill buy a lovely block of 17 kg foam , ( no gluing ) , .
When I was filling and fairing my current project with two part foam, I mixed up a bad batch. It continued expanding in little bits and pieces for a few days. While it didn't affect me, it does make me wonder if your foaming glue deep inside the foam had not been able to fully cure buried deep inside the board and the heat provided the catalyst.
I'd be tempted to let it sun for a few days open and then seal it up. It's not going to be generating this much excess gas indefinitely.
It's been fun watching your progress. Sorry you hit this bump in the road.
^^^
I think your onto it with the uncured foam . It can't keep fizzing forever .
It will be a massive project . I can't inject resin , it will weigh a ton and the lam stretched so much it wont push down.
I will have to take off the front half of the top from middle of mast track . At least the blank will have a layer of glass to start with .
I'm going to do it
Once the top is off I'll drill a lot of little holes through the remaining glass layer and let the Fkr roast in the sun for a week . Then re sandwich and glass over . One good thing is that the rails are thick with layers of glass which will be solid to feather out .
There is no way I could color match the operation , it's going to take ugly to the next level .
I dunno why but your board reminds of the kid from willy wonkers that blew up and floated away.
Maybe fkd rebuilt can be marketed as air inside
Select to expand quoteGestalt said..
I dunno why but your board reminds of the kid from willy wonkers that blew up and floated away.
Maybe fkd rebuilt can be marketed as air inside
I should call it BLOWNup not FKDup
or
Full of gas , like me 
OK , so I've stopped crying and picked myself off the floor
Just a tiny effected area 
Now roast in the sun ya fkr ! Actually it might be a better idea doing this slowly to begin with . All other areas are solid , bottom is perfect .
Now I'm sure its the foam glue I used . I confirm this because it happened at the front where there were a few foam layers exposed from the upwards curve . Also it was on the top where the sun was , leaving the bottom undamaged .
The expansion must have been fast and aggressive .
Bottom pics reveal the monster .
So I'm going to let it vent for a week ,or more , slowly . Pick out damaged glass , bog it up , divinycell and glass over .
In this spot where the foam layers were glued together it literally blew a hole up. Its the size of a fifty cent coin . Half way round it broke the glass .
This ridge , ( about a foot long ) , is also along a join . You can see the wrinkles in the glass layer . Under the wrinkles the foam is pushed down a couple mm. The pressure must have been huge .
use either
www.bunnings.com.au/gorilla-236ml-glue-bottle_p1662679
or
www.bunnings.com.au/tarzan-s-grip-480ml-mega-bond-ultimate-strength-glue_p1210340
next time you want to glue a blank up. Or any similar polyeurathane wood glue from Carbatec or similar type specialty shop.
Imax,
Sorry this happened to your fkd up board build.
As the recovery work removed the stencil, presume the replacement stencil will be FKR.
Am enjoying watching and learning from your progress. Best of luck with the recovery.
Hey IMAX yes it must have been crazy WTF to see board blow up but a retired man in sunny Queensland will rebuild and sail.
As a "glass half full" it can give you a fine tune in design for your next project which you won't be foam together pieces.
Imax, great post - inspirational and it's a shame it fkdup. It sounds like you worked out what the issue was. Do you think there is a risk with gluing up a blank that the glue creates barriers within the blank preventing it from breathing evenly over the full length or perhaps preventing the gas getting to the vent?
^^^
It could be a bit of that , but I'm now sure it's the expand foam glue fumes . I built it quite quickly after glueing the blank together , sealing in the fumes . Then when heated in the sun a second reaction happened . I believe if I roasted the finished blank in the sun it would have been ok. The not so funny thing is , it didn't take much heat to make it go nuts.
Im still worried that after I fix it , it still may release some gas . The last 3 days it's been in and out of the sun on an hourly basis I'll do this for another couple days then leave it all day cooking , both sides for a couple days . I got to make sure the glue on the inside of the blank has finished gassing.
I guess you could seal it up in a plastic bag to test for gas before Un-FKDing it.
Road to recovery .
I just spoke to another board builder and he knows of this happening with expand glue in a can . Secondary reaction releasing lots of gas .
This has turned from a board build into a , " how to fix a major stuff up ".
Its been sunning itself for a week. Three days all day in the sun . I hope that's it for gassing. I'm still a bit worried . Even though I'm a leave the vent in sort of guy , on this board the vent will be out for quite a while unless on the water and try and leave it in the shade unless sailing . Just my luck ill forget to do it up !
The wonky outline is where the delamination ballooned .
Top bogged and sanded smooth .
Divinycell core cut to size .
Edge of board taped up .
Core glued down with q cell thickened resin .
Mummification . Poor mans vac bag.
Select to expand quoteImax1 said..
Road to recovery .
I just spoke to another board builder and he knows of this happening with expand glue in a can . Secondary reaction releasing lots of gas .
This has turned from a board build into a , " how to fix a major stuff up ".
Its been sunning itself for a week. Three days all day in the sun . I hope that's it for gassing. I'm still a bit worried . Even though I'm a leave the vent in sort of guy , on this board the vent will be out for quite a while unless on the water and try and leave it in the shade unless sailing . Just my luck ill forget to do it up !
The wonky outline is where the delamination ballooned .
Top bogged and sanded smooth .
Divinycell core cut to size .
Edge of board taped up .
Core glued down with q cell thickened resin .
Mummification . Poor mans vac bag.
Select to expand quoteImax1 said..
Road to recovery .
I just spoke to another board builder and he knows of this happening with expand glue in a can . Secondary reaction releasing lots of gas .
This has turned from a board build into a , " how to fix a major stuff up ".
Its been sunning itself for a week. Three days all day in the sun . I hope that's it for gassing. I'm still a bit worried . Even though I'm a leave the vent in sort of guy , on this board the vent will be out for quite a while unless on the water and try and leave it in the shade unless sailing . Just my luck ill forget to do it up !
The wonky outline is where the delamination ballooned .
Top bogged and sanded smooth .
Divinycell core cut to size .
Edge of board taped up .
Core glued down with q cell thickened resin .
Mummification . Poor mans vac bag.
Gutted for you Lmax! .... just curious... what did you glue the divinycell down with the first time?
^^^
Contact adhesive . I've done this a few times before and works good . Vac bag less . Just adds a little more weight because I roll on a thin layer of resin over the glass layer . Have to make sure the blank is sealed for the glue .
Select to expand quoteImax1 said..
^^^
Contact adhesive . I've done this a few times before and works good . Vac bag less . Just adds a little more weight because I roll on a thin layer of resin over the glass layer . Have to make sure the blank is sealed for the glue .
This may be part of the problem then.... It could be also that your spray foam was off gassing but I suspect the highly porous H80 Divinycell has poor adhesion using the contact cement. I have even seen vacuum bagged boards delaminate like this when not enough resin was used in the bonding layer. I like your troweled approach to fix it though. Another way which has worked well for me was to pre-seal the Divinycell side with a microsphere epoxy slury before laminating... with a bag you can do it all at once: pre-seal the blank, pre-seal the Divinycel, laminate the glass onto the blank, align the Divinycel, throw it in the bag wet.
Sounds like the outside glass and d-cell layer expanded when it got hot in the sun, and the contact glue did not hold it down on the glass below. Contact glue generally remains elastic, which would allow the top layer to move away from the center as it gets warmer. Since the d-cell is more porous than what you've used before, there was more contact glue, or some air remaining. Either one will allow the d-cell to move away from the glass much more easily than if you had used epoxy.
The delaminations I have seen were all between the glass and the EPS core, either because not enough epoxy was used to get into the EPS, or because the EPS was crushed from heavy use. I have not seen a delam between the d-cell and the glass. Would not really expect one, either, with epoxy, since the connection between the d-cell and the glass is a lot stronger than between the glass and the EPS. My experience with delams is limited to only 3 boards, though.
