Ok got the fin box
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I cut the hole with a fine tenoning saw as another site sugested that the router would blow shards of glasss into the eps & it was pretty easy & i couldnt be bothered taking the router off the table saw & i didnt want to hit the plugs
I know its a massive hole but the eps was torn out that far on one side
dont really understand the varing thickness of the divicell
I will measure tomorrow but if the glass is more than .5 of a millimeter I would be suprised
I hope to get the rest off the stuff tomorrow
plan is trim fin box to fit deck right height .
fit divi cell to deck cut slots to suit for foot strap
cut fin box hole
glass fin box to deck which shouldnt be to hard as i can bolt throught the deck to hold it in place i hope refit divi when happy with epoxy into place .
As i cant really see how to glass finbox to deck with divi back in place.
The thicker d-cell is to help support the box at the bottom.
Putting the box in first is an interesting idea and should work OK.
On a new board I leave the box full size, put the 80kg/m3 foam in then router/cut all the way through the deck, then cut the box level with the deck.
Seal the hole in the deck with plastic and tape.
round the bottom edges of the hole, glass/carbon the bottom.
Wrap the box in 2 layers of 150gm glass with enough to overlap into the bottom about 2cm to 3cm, I rebate the bottom to accept this extra glass before glassing.
wet out the hole, wet out the cloth and pour some resin into the hole, lay cloth over hole and insert box.
weigh down a bit of mono film over the glass overlap and box.
I then glass/carbon over the deck, this really ties the box to the deck, but in your repair situation would entail more cosmetic problems, and you also have the existing plugs to consider.
i'm surprised you had problems with that box
For some thing like that I would get a can of poly urethane foam from the local hard ware store and fill in the hole, keep stirring the foam in the cavity, the foam will get denser and about as hard as diviny cell. did three boards last weak end, one with ripped out fin box, two sandwich boards where the polystyrene was crushed under the straps, but dont use it on closed cavity's, might blow the board out.
Boards finished . Ankles good enough to test . The end result is im happy with the job i did has to be a million times stronger than the original. Its was an expensive repair that this board can only just justifier. Still got some spare material so it will work out cheaper in the long run . Makes me want to strip another old board & reposition mast track & footstraps . I took a lot of pictures that i can post of repair if anyboady wants them otherwise i couldnt be bothered .
block made 50mm thick klegi cell expensive but strong as & light i was lucky to get a offcutso two blocks to get thickness
fin jig for box to deck
block fitted
plenty of qcell pushed out under weight
cleaned up for second layer
feathered out for glass
3 layers carbon fiber 200g
finished board didnt polish i cut it back with 1200 wet& dry
couldnt be bothered at this stage replacing graphics although i have traced pattern
