Although I'm not a professional at board repair, I did come up with a pretty solid repair to the deck of my board recently. In this case the board developed a soft spot from my toes at the front straps from freestyle sailing.
Upon investigation I found that the foam had compressed enough to pull away from the fiberglass. I cut back the fiberglass sandwich until I got back to the region with good bond and no delamination. From here I feathered back the sandwich to have a good bonding area. I also cut out a matching piece of 1/8in plywood to take the place of the old deck. It's amazing how easy it is to cut the 1/8in plywood with heavy duty sciccors.
From here I used a spray foam to bring the surface up flush with the rest of the deck. After setting, I sanded the foam down to be inset just the thickness of the new 1/8in plywood plug.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgunW3gWBD11vB2da-KHaRuVt8NPDwd4plYiE98LO6o4e8gO1NggNb9jUP62WUSUYKwzjuBbgTvfQtAEv319_cws4TWg2EhlqQB1r3rT0gUbmwvyUFuT-bt5T52aPmV1Q2L0iO7HzfC9DY/s320/Board+Repair+001.jpg)
After sanding the new foam back I then layed the first layer of fiberglass into the repair and allowed it to come up the sides of the repair and onto the existing deck of the board.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-72g9DuWHeLikEgC_UVdtZoJbUL7VU-rPlS0kQFj69JwAeZa4Rj5VrPpDYe4x1JDroXoNAjlRGx-HalCnPEtmJ7a3M2hwTLtA4lIoINPoSfnY85RMQJAqutBsgFiE8E6jie5o0OYUmaE/s320/Board+Repair+002.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoTLM9gjTtUf1BizZQv1iAPx8A1vX9KuLk0qPKJKIl8AqG2wVDhH4adkhXoh1CJq-MzBjPikKZZ2e_9Zd3icWG167NCaQGBipQHXL2MEWsS8deEoocuTZpZOg3ZHTCnwdk2LpLesDXbi8/s320/Board+Repair+003a.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRLngUKzQvmkRh3yrpJVMZ01zEpcD3nrmrr1FytQ0LnFhogntsH2DBy5l9ZagHBE21cNcDAftnprXRzkCHTS1aKxsqD2zXcd3AlUFx3q3AhJAlwidXyC-Zg6IMEMc49FraaAuir_-QBgY/s320/Board+Repair+004.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYEn8JnoRwyy71rAVOS98GlA1KKFYcMTL0_whkE8V8C9qTZE3V9GoXO1vZjKuDPlCbFRgBI19Yk2tRr0Mr1V51hbTk4M-JPdeyk1afG5tjkJWXGdSDLu1bcXRn-axn7YUhSxShv7-3pMo/s320/Board+Repair+005.jpg)
I then placed the plywood into the repair and weighted it to take the rounded shape of the deck.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNYuDwz9Bur6RRVM6cze5RZOfqCwWvwJ82YxBGxRPCLAEKl3LicxTk2XeRDSi-iqGOY-GP54DUegUpqYW82G73m-orAigdWnQKRZOsu93gDc8ox-slHqAI0wbFOrf5Mld-qWJoMJ3KQf4/s320/Board+Repair+007.jpg)
After this was set, the final step was to glass over the plywood and the entire repair to finish off the sandwich patch.
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