Nugg Turbo "Repair" Disaster Turns into "Rebuild"

[StarboardSUPMan]

Here is the update.  I’ve completed the fix, it’s very strong, didn’t add a lot of weight (still need to weigh it) and it looks pretty good.  I didn’t buy all the materials I had fiberglass matte and all the tools I just need resin but total cost would be under $100 even having to buy it all.  Bought the epoxy from uscomposites.com.  I can’t say this was the best solution, I took it step by step and only went as far as I had to.  Looking back on it, just completely removing the entire deck back to foam and re-glassing wouldn’t have been anymore difficult.  (Having issues uploading pics just provided URL's instead for now)

1.  As shown prior the first step was to mark out where the foot dents were and remove the deck pad.  The fastest way I found to do this was with a 9” grinder with a sanding disc. 
2. Next step was to push down on the board and find all the spots the fiberglass had delaminated.  Since these spots were small and there were only 3 places I decided to not remove the entire bamboo veneer.
3. I took my dremel tool and cut out the spots that had delaminated to take a peak at the foam underneath rather than just filling with gorilla glue/epoxy resin.  I dug out the damaged foam and shaped some replacement foam to fit (bought at Lowes high density foam). 
https://drive.google.com/open?id=0B6QSCGzP_ZjeeVdsY0tmRldnUHM
4. I wet the foam and gorilla glued them, placing heavy objects on top (window washer fluid, pain cans, etc).
https://drive.google.com/open?id=0B6QSCGzP_ZjeQ3pIc20zU1FoWnc
5. After drying I sanded down the foam to be flat (about 1/16” less than the deck so the veneer sat flush).
https://drive.google.com/open?id=0B6QSCGzP_ZjeVTFoR3FhRkJ0NWc
6.Then I put 1 layer of glass ontop of the foam, and the bamboo veneer ontop of that.  I also epoxied a piece of 1/8" wood where the handle had split.  Again sat heavy objects ontop of it overnight to compress it.
https://drive.google.com/open?id=0B6QSCGzP_ZjeWlF6N1E2NktYVUU
7. First mistake came to light, one of the bottles of window washer fluid fell off before the epoxy kicked off so it didn’t stick.  Had to cut out, sand and re-do.
https://drive.google.com/open?id=0B6QSCGzP_ZjeN015MDJRQ1FRbEk
8. Since things weren’t as smooth as I’d hoped I glassed 3 layers ontop of patches
https://drive.google.com/open?id=0B6QSCGzP_ZjeTzRpSWlMTzMtWW8
9. Sanded those layers smooth so the deck was as smooth as possible.
https://drive.google.com/open?id=0B6QSCGzP_ZjeZHBTeHVhZFNDZ00
10. Next up layed 4 layers in each foot well to build it up (cutting each layer a little larger 1” or so than the last).  Then 3 layers over the entire deck, again smallest first then 1” larger.
https://drive.google.com/open?id=0B6QSCGzP_ZjeSml1M2lfNXlJZWc
11. Second mistake.  I realized I didn’t feather the fiberglass back enough so I had soft spots where the board didn’t get enough glass.  So I sanded back another 3-4 inches around the entire board removing more deck pad being careful to make sure I didn’t sand too much.  Also even with 3 layers of fiberglass the board wasn’t as strong as I’d hoped
https://drive.google.com/open?id=0B6QSCGzP_ZjedndKQUtadkowdXc
12. Now with everything sanded I layed 4 more layers of matte ontop going down and inside the carry handle so it wouldn’t split on the edge anymore
https://drive.google.com/open?id=0B6QSCGzP_ZjeRjJscVVMS0FTSzg
13. Sanded it down and did a hot coat overtop
https://drive.google.com/open?id=0B6QSCGzP_ZjeNUQ3dkQ1WC11V2c
14. Sanded the hot coat with 400 grit sandpaper
https://drive.google.com/open?id=0B6QSCGzP_ZjebWJjQ0RVdUhGNmc
15. Spraypainted it
https://drive.google.com/open?id=0B6QSCGzP_Zjebk9UVHZTZThwQjQ
16. Re-applied a deck pad.
https://drive.google.com/open?id=0B6QSCGzP_ZjebHhwcWh5Vlg3Ulk

Hopefully this helps some others out.

[Newps]

Nice job guys, your repairs are excellent.  I suck at doing repairs and have given up. 

I have a great local guy who fixes all of my boards.  Price is good and we always get to catch up and talk. 

[Zooport]

Looks like you did good quality work and the end result looks nice, almost like it never happened.  Congrats.

[StarboardSUPMan]

I wish I had weighed my nugg prior to the fix but I did weigh it after.  Came in with pad and fins at 24.3lbs.


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[The Kernel]

Super rebuild job! 

Yours came out WAY lighter than mine...Kudos!

[SlatchJim]

I love this thread.  Thanks guys. Just got the supplies needed to do a few repairs on the fleet myself.  I have the 4th of July free, since I'll be in full crowd-avoidance mode. Hoping to get the dings cut, sanded and filled.  I've done too many quick fixes in the past that I haven't been too proud of, and it's time to up my game a bit.  You guys provided the needed confidence to venture forth into the unknown.