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The Honolulu Advertiser
Posted on: Monday, January 28, 2008

Do away with dings

Photo galleryPhoto gallery: Surfboard repair
Video: How to repair a broken surfboard

By Mike Gordon
Advertiser Staff Writer

Hawaii news photo - The Honolulu Advertiser

Board Works owner Brian Ikeda holds up a surfboard after all the necessary repairs have been made. The ding repair specialist fixes three to five boards on a typical day.

Photos by CHRISTINA FAILMA | The Honolulu Advertiser

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Hawaii news photo - The Honolulu Advertiser
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Hawaii news photo - The Honolulu Advertiser

Ikeda removes the damaged foam cells from the surfboard using a Dremel high-speed cutting tool, a must-have in his repair kit.

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Hawaii news photo - The Honolulu Advertiser

Ikeda uses a resin mixture to fill in the damaged area after sanding it down and drying the exposed foam.

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Hawaii news photo - The Honolulu Advertiser

Ikeda adds on a dual fiberglass layer.

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No matter how careful they are, whether they're riding a large wave or an ankle-slapper, sooner or later surfers ding their surfboards. On the reef. On the water. On another surfer's board. Even doorjambs can take out a chunk.

If you're Brian Ikeda, this is a good thing. The surfer's inevitable calamity is Ikeda's job security. He's a ding repair specialist with a thriving business in 'Iwilei. On a typical day, he'll repair three to five boards.

The 53-year-old Ikeda, owner of Board Works, can take a buckled surfboard with a thumbprint-wide crease across its midsection and erase all signs of damage. He actually likens what he does to dentistry, although it's something closer to art.

But the average surfer can do this at home, Ikeda said.

The key to successful repair of a traditional, fiberglass and polyester resin surfboard is to understand the two basic types of damage, the goal you're shooting for and the way that your repair materials work together, he said.

Ikeda divides repairs into non-structural, which are cosmetic damages, and structural, which is a broad term to cover any kind of gouge you can imagine. In either case, you need to rid the board of any damaged foam, fill the ding with new material and re-seal the board's fiberglass skin.

"If you're not picky about the outcome, anybody can do it," said Ikeda, who fixed his first board when he was 10. "If you are going to do it yourself, it will take time. But it's not that hard."

For all the fun that can be had gliding on water, if you compromise the skin of a surfboard, water quickly becomes the enemy.

"The whole deal is to keep water out of your board," Ikeda said.

Salt water can damage the foam inside and the impact that created the ding more than likely destroyed the foam in the area. Crushed foam cells are worthless and need to be removed, Ikeda said.

"You go to a dentist and you have a cavity, he's not just going to put a cap on, right?" he said. "He's got to get in there and start from the root and go out. It's the same with a surfboard. You repair from the inside out."

If working to ensure a dry foam core sounds laughably simple, consider that Ikeda has seen scores of repairs where the water was still trapped inside. Trying to dry the board without exposing the foam to air turns your repair job into a waste of time.

"It's going to stay wet until you open it up," he said.

As with any home project, repairing your surfboard will be easier if you have the right tools.

Ikeda's favorite piece of equipment is his Dremel high-speed cutting tool. Its quarter-sized blade easily cuts through fiberglass and it can be used to carve away damaged foam. It will set you back about $100, but without it, you'll have to use a utility knife or a block sander.

Another must-have tool in Ikeda's ding-fixing kit is his orbital sander. Given that repairs involve several steps with sanding, a 5-inch orbital sander will speed the project along. You can get one for about $20.

All repairs should be covered with fiberglass cloth soaked in resin to seal whatever fill material you have placed in the damaged area. Not only will this strengthen the board, it will prevent the seam around the repair from developing cracks that will let water in, Ikeda said.

Ikeda is a master of the seamless finish. His customers always ask him how he does that.

His secret? Two layers of cloth with the top layer extending further out than the one underneath. If he used only one layer, he'd bump into the repair. With two layers, he can blend them into one with his orbital sander.

"You never see the edge," Ikeda said. "It rises slowly. This way it won't look like a Band-Aid."

• • •

Make repairs at home

Here's how to repair structural damage to your surfboard.

STEP 1 — Clean the wound: Use a ruler or a right angle to draw yourself a cutting guide about one-quarter inch away from the damage, then use a Dremel cutting tool to cut along the line. Be sure to wear safety glasses and a respirator. Using a pick, peel away the fiberglass. You can substitute for the Dremel by putting a blade attachment or sanding barrel in a drill motor, using 60-grit sandpaper on a block or wielding a utility knife.

Wet foam will need time to dry. Set the board aside for a few days in a cool, sheltered area. Don't cover the exposed ding. Ikeda uses an air compressor to speed up the job but warns that if you do this, you need to be careful that the blast of air doesn't peal away more fiberglass from the foam.

When dry, scrape away the soft, damaged foam cells until you get to hard, undamaged foam. Ikeda uses his Dremel blade, but you can use sandpaper. Remember that the more foam you scrape away, the more you will have to replace.

Use 80- or 100-grit sandpaper to clean the edges of the exposed ding.

STEP 2 — Build a dam: With blue painter's tape, mask off the exposed ding, putting your tape about an inch away from the ding. Then use the tape to build a dam around the area. You want it high enough to contain the resin mixture. Be sure to secure it firmly to the board, because resin will find cracks in your dam and leak out.

STEP 3 — Pancake batter: In a paper cup, mix polyester sanding resin and Q-cell — a light, flourlike resin thickener — until your fill material is the consistency of pancake batter. Add color tinting, if desired. Next, add catalyst. How much catalyst you add depends on the amount of resin you are mixing. Follow the instructions on the resin can. Next, pour the mixture into the dam. Spread it out with a flat stick and be sure the mixture goes into every crack and depression around your ding. Make it about one-quarter inch thick.

As the mixture begins to harden, remove the dam and use a rasp to sculpt the mixture into the shape of your board. Ikeda recommends the mix be about 80 percent cured — firm enough to touch without sticking, but definitely not rock hard. If it's too soft, the rasp will pull the material out of the ding. Use a rasp long enough to provide consistent coverage of all the high areas you're shaping as you bring the board back to its original shape.

Next, block-sand with 60-grit sandpaper to refine the shape. You can feather the edges with 100-grit sandpaper.

STEP 4 — New skin: Mask off the area around the newly filled ding with blue painter's tape. Set the tape back a few inches, depending on the severity of the ding. You need enough space for two layers of 4-ounce fiberglass cloth. Make the first layer smaller than the top layer by a few inches. The idea is to create a gentle slope that is easier to conceal when sanded. Mix your resin and catalyst per instructions and pour onto the cloth. Use a squeegee to gently press the mixture into the cloth. Be sure to avoid leaving dry spots or air bubbles.

When the resin-cloth mixture is 80 percent cured, use a utility knife along the edge of your painter's tape to trim away excess material.

STEP 5 — Smooth and shiny: With an orbital sander and 80- or 100-grit sandpaper, smooth your repair. The two layers of cloth should allow you to feather the outside edges as you work closer to the center of the ding. At this point, you are ready for a thin coat of resin. Tape off the area, then mix resin with catalyst according to directions. Brush on a thin coat. Don't worry about the brush strokes as the resin will spread out, smoothing away any lines.

When cured, sand with progressively finer grits — 100, 400, 600, 800 and 1,200 — until satisfied with the finish you have created. At that point, you can use rubbing compound and car wax to bring out the shine, wax your board, and go surfing.

Reach Mike Gordon at mgordon@honoluluadvertiser.com.