How to Repair Fiberglass on a Windsurfer

Windsurf boards are generally used in rough waters and commonly get damaged. The boards are constructed out of foam with a thin fiberglass shell. Fiberglass is a very durable and strong material that has the ability to be repaired back to original strength fairly easily. Fiberglass is applied in layers of a dry fiberglass material that's individually wet out with catalyzed resin. The resin hardens and bonds to the original fiberglass surface forming a strong repair that will last as long as the rest of the board. Fiberglass repair kits for surf or wind surf boards can be found at your local marine supply stores or surf shops.

Instructions

Difficulty: Moderate

Things You’ll Need:

Respirator 100-grit sandpaper Rag Acetone Fiberglass mat Rubber gloves Small bucket Fiberglass resin Catalyst Stir stick 4 Inch felt roller Air roller 200-grit sandpaper Gel coat Paint brush 400-grit wet sandpaper Board wax Electric buffer
Respirator
100-grit sandpaper
Rag
Acetone
Fiberglass mat
Rubber gloves
Small bucket
Fiberglass resin
Catalyst
Stir stick
4 Inch felt roller
Air roller
200-grit sandpaper
Gel coat
Paint brush
400-grit wet sandpaper
Board wax
Electric buffer

Step 1

Put on a respirator and sand the damaged fiberglass smooth using 100 grit sandpaper. Sand down any rough edges and completely scuff the surface of the damaged area.

Step 2

Clean the surface of the repair using a rag that's damp with acetone. Let the surface dry.

Step 3

Tear two layers of the fiberglass mat to the size of the damaged area. If the damage is deep add as many layers as it takes to get the damaged area level with the surrounding fiberglass.

Step 4

Put the resin in a small bucket and add the catalyst following the recommendations on the containers. Use a stir stick to thoroughly mix the resin.

Step 5

Wet the surface of the repair with the resin mixture using a 4-inch felt roller. Apply the first layer of mat and saturate it with resin using the felt roller. Flatten the mat out and remove the air bubbles that will be trapped under the mat using an air roller. Follow the same process for each layer until all the mat is applied to the repair. Let the fiberglass cure until it's hard and cool to the touch.

Step 6

Sand the fiberglass smooth using 200-grit sandpaper. Clean the surface with a rag and acetone.

Step 7

Add the needed amount of gel coat to a small bucket and add the catalyst following the recommendations on the containers. Thoroughly stir the catalyst in using a stir stick.

Step 8

Apply the gel coat to the fiberglass repair using a paint brush and let it harden. If the surface of the repair is still lower than the surrounding fiberglass, apply the necessary amount of gel coat to even out the surface of the repair and let the gel coat harden for 24 hours.

Step 9

Wet sand the surface of the repair using 400 grit wet sandpaper until the repair blends in with the surrounding surface. Wipe the surface of the repair clean using a rag and water. Let the board dry.

Step 10

Apply 2 to 3 coats of board wax and let it dry. Buff the board out using an electric buffer until the surface reaches the desired shine.

Tips & Warnings

Wear rubber gloves when working with catalyzed materials to avoid chemical burns.

Article Written By Jay Kurz

Jason Kurz has been a published writer for eHow.com and Trails.com for less than a year now. Kurz attended Kent State University of Ohio for Computer Aided Design.

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