delam and filleted bonzer

Because this was my favorite board, I started using it more. And one time, just once, I forgot to take the vent plug out after use. A few days in my hot garage was all it took - major delam on the bottom!

So I had to strip and re-glass. The mermaid was gone, but I decided to paint her again, which is a bit of a project!

However, it occured to me to try something else, while I was at it. Opening the board up, and doing some weight loss surgery. Sounds crazy I know, but I did it, and am just about ready to re-glass.

longboard rebuild - broke in 2 at Malibu!

This longboard was donated to me after it was broken in two nightsurfing Malibu.

Since applying my "Bahrman Rails" method to a foam and glass board, I've been wanting to explore a little more the union of wood building techniques with conventional foam and glass surfboards.

I thought a broken foamie would be the perfect guinea pig - since many of us woodies are into it for environmental reasons, I figured salvaging a petrochemical byproduct from the landfill, and creating a surfboard from a recycled wreck would be a worthy cause.

I did not have a camera during the rebuild. So I have no "in progress" photos. Hopefully I'll get another chance to do this, and I can share my photos of the process.

I glued the two halves back together with epoxy resin. Clamped the two pieces down in place, but didn't mask it off well enough before I poured my resin,and it seeped out and ran over everything and made a mess. But it stuck together anyway, even 'tho it was a weak joint. So then I cut out a 12" section of rail on each side, and replaced it with redwood, epoxy-glued in place, then shaped the redwood to blend in. It was still a weak joint, and you could tell when handling the board.

To beef up and stiffen the repair, I cut a "stringer" slot out of the middle, about 3' long, 3/4" wide, and slid a piece of 3/4" cedar in, and epoxied it in place with 5 min. epoxy glue.

Then I cut a diamond shape out of the composite deck surface, the length of the new "stringer" (3'), and epoxied some thin redwood and cedar planks down, then blended them in once the glue dried. On the bottom, I just filled the glued repair area with bondo, sanded it, and painted it white to match.

I'm sure I've added a few lbs. to the board, but I'm not too worried about it, it still feels good.