A mate, against my advice and much to his regret, used a Deviator which promptly levered the mast track partially out of his Fanatic. He has expressed his remorse (no need to beat him up) and has asked my help in getting the board back on the water.
In scouting around the 'net, I've found several ways including nesting the new track in layers of glass bedded into a paste of Q-cells; and gluing layers of PVC foam (e.g. Divinycell) around the new track and then bedded into cells but not necessarily any layers of glass. I think enough of the original high density foam remains in decent condition to work with (and if not - my second question below). IIRC, a couple of board builder's videos just have the track bedded into the high density foam without glass or PVC foam surround.
So, a couple of questions:
1) Is there a preferred method by the gurus of board building and repair here?
2) Since I may do a voluntary move of a track on another board (to make the board more suitable for foiling) what density of foam is generally used to bed the track into? Usually, when I see any board building video, there is a brief mention of "high density" foam but I can't find any mention of what that density actually is or where I might find such a thing.
We have ordered a fresh Chinook track and have standard supplies of slow hardening epoxy and 4 oz glass.
glass only helps if it's wrapped around onto the top of the deck. just wrapped around the box, only strengthens the box, and a chinnook is strong enough. If you're not using high density foam, then several layers of glass around the box and onto the deck by about 2cm should be OK as long as the hole is well wet out so no water can leak into the core.
High density foam is a better option as it's closed cell and acts as a water barrier to the core.
I'd go for at least 40kg/m3. But you could be more confident with 80kg/m3
It is hard to come by though in small blocks.
Easier to get hold of is 2 pack expanding foam, also easier to put it in. Just dig out a hole at least 2cm wider than the box all round.
The stuff I've got expands about 30X so it's just a matter of measuring the hole volume and divide by 30, then add a bit for good luck.
route out a hole and fair the surrounding edges about 2cm allround...... sink in a new PVC block with microballoon paste ....drop your track into the pvc with microballoon paste ... cure and clean up. Then Laminate with 2/3 layers of 200gsm glass or carbon. Clean up and go.
The PVC in my opinion is key.
Pain in the ass but its actually a pretty quick job.
