Board repair gurus please help

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Mark _australia said...

OESaustralia said..
Just glue a nose block of Divinicell onto the end of the nose, once dry reshape the divinnicell to the nose shape you want, then glass top and bottom with 6 layers of 4oz glass, sand, then paint.

Yep that's what I was thinking when I looked at that repair blog, was trying to be nice when I said overly complex.....
Trouble is, I find it hard to get big blocks can only get sheets up to 10mm thick. Any leads on bigger stuff?

I've got some for ya Mark just give me a shout

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needsalt said..
Thank you all so much.

Today's silly questions. Excuse my ignorance, but without having seen any I'm just not sure. Once I stick on the divinycell nose block, how do I shape it? Cut, sand, heat gun? A hair drier can double as a heat gun for some purposes. Would it do the job here?

Do I need to seal the foam with a layer of glass before applying the divinycell?

Can I get by with the blue masking tape, or should I try a DIY vacuum bag?

I promise I'll reward all this fantastic advice with more board repair horror photos for your entertainment and amusement soon

If its a block of divinycell or layers of it, you will shape it the same. It is a stiff material and breaks easily if you try and bend it. When Keef was suggesting a heat gun he was talking about warming the sheet up so that it follows the contour of the board. The thicker the sheet of divinycell is, the harder this will be. This will not apply to your repair as you are not trying to follow a curve, you are gluing it to a flat, and then shaping it.

If you glue on a block of diviny, or multiple layers, you will need to sand it. You can cut it with a hacksaw to get a rough shape, but you will need to shape it with a sander or sandpaper and a sanding block.

I have never used glass under the diviny to foam join, although others seem to recommend it. In your case you are going to glue the diviny to the foam, and it might be a bit difficult to add the glass as well. Without a vacuum bag, it is easy to make voids which are just going to reduce strength.

I think the easiest thing for you to do, is to glue the diviny on, whether in one block, or in layers. Once it has gone off and firmly stuck in place (when the epoxy has set, probably in a day), you can then shape it. If your shape has holes in it, or you have gaps, fill them with an epoxy/filler paste, and let that set. Then sand it to shape, and then apply your final layers of glass and epoxy.

One thing I do, is use really cheap paintbrushes to paint a thin layer of epoxy onto divinycell, before applying the epoxy/filler paste. It seems to stick better this way and you can use a drier (less runny) paste than you otherwise might be able to .