[quote=DanBerger]I keep hearing my name tossed around!? I'm glad you got a good deal on the new boards, I do have a pair and pretty much an entire Solcat 18 parted out.
So, although that is a very ugly fix, it isn't that bad--as long as the piece is still on, you just have to epoxy it back together but don't skip on the glass!! I would grind out 2 inches from the crack, and even grind inside the crack to get the surface clean. You should open up the crack and have some space between the two edges.
Then, put the board in a jig so that it will hold in it's final shape and I would use thickened epoxy to fill in the crack gap and lay a layer of glass over the gap. Work epoxy into the glass from above and let it cure. repeat for the other side. This should make the board pretty stiff and you can work with it without changing the shape. Next, sand down the glass layer and using unthickened epoxy, add at least two more layers of glass to fill in the part you ground off around the crack. That will address the crack.
On the bottoms, I have had a lot of success grinding away at the sides about an inch up all the way around. Use thickened epoxy--By that, I mean add that ground up brown filler West Sells. Make it thick, peanut butter viscosity is too much. smear the thickened epoxy on the bottom of the rudder and use packing tape to kind of give it a shape. also, work it into the cracks on the bottom and tips. I do that for each side and I build it out a bit too much so I can grind it back to it's expected shape.
The real trick is to thoroughly clean the old glass--it looks like the previous repairer did not do that so the epoxy failed to adhere. Don't be stingy on using Acetone to clean up the area, too.
To finish the board, you should sand the entire thing with 100 grit to roughen it up some, then you an roll on Gel coat and sand it smooth with varying grits until you get to like 2000 grit.
Or-- since working with gel coat in that manner is pure madness, I would spray it with white appliance epoxy--hit is with several coats and pay attention to the cure time on it. You have like 20 minutes between coats or you have to wait a week to apply another coat. You will have to wait a week before you can sand the paint to get out imperfections.
Hope this helps.[/quote]
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