Blue Chip Repairs
The repair procedure detailed below is standard for us and has been continually improved and developed since 1980. Only by using the best materials available along with our proven processes and experience can we offer our customers every confidence in our repairs. You can be assured that like an iceberg, the repaired area you see on the surface is dwarfed by the work that has been undertaken below the surface of your board which cannot be seen. 

One thing you can be sure of, we don't use car body filler to repair boards...
 

As a rough price guide
Full Nose job on say a JP: The following procedure ensures the very best strength to weight ratio and undoubtedly gives the board a much improved impact resistance in the repaired area
Time scale about 2 weeks:
Weight gain approximately just 100g:
 

         This is the chronicle of a board which arrived with us looking like this;
                  you can follow its progress as you scroll down the page...
                                   Click on any image to enlarge
  

We remove the underside of the nose including the EPS core to expose the full extent of the damage including any previous unsuccessful repair attempts. All loose materials including previous repair materials are removed. In this way we can start from a clean and sound base.
 

Then we laminate the underside of the exposed deck with 100%  320g woven multi axel Kevlar and then 100%  275g woven multi axel Carbon:

Note:
The Kevlar we use is "ballistic grade" which gives the best impact protection and the Carbon we use at this stage is multi directional which affords great structural stiffness. These two key materials are laminated between layers of 160g woven glass and are cured under pressure to remove the unnecessary resin to form a powerful and light structural laminate.
 

  100% Ballistic Quality 320g Kevlar         100% 275 Carbon Woven Cloth
   

We then re-foam the core with a high density EPS foam to give a sound and substantial inner core without adding unnecessary weight. The shape of the replacement core is critical, if the replacement core is too small, the final stages of the repair would require over use of topcoat finishing materials which would not only add weight but also leave the outer shell of the repair brittle.
 

Then we re-skin the underside with 2 layers of  160 glass 1 layer of 300g stitched glass and 1 layer of uni directional Carbon, at this stage we also introduce adhesive additives to where the laminate and the original construction meet, this helps key the whole laminate onto and into the original construction. The entire repaired area is then put under pressure during the curing process to form a proven and strong monocoque construction:
 

 

This type of nose re-construction gives the best strength/weight result without any exterior changes to your board. average weight gain with this procedure is about 100gms. Total time in our workshop will be about 14 days and the cost for this type of repair procedure  will range from about £120 to about £150 depending on the collateral damage we are presented with.

 

Of course, there are other ways to fix a board with this type of damage. Different manufacturers construct their boards in different ways and therefore require different repair methods, which must be sympathetic and strengthen the original construction. Our approach to board repairs is very much dependant on the original construction and seeing the board first hand, then we can advise and recommend the correct repair procedure in each particular case.

Cheaper ways to repair a board:
We could just repair the visible damage on the outside of the board, leave out the Kevlar or the Carbon, use a less dense EPS replacement core, use less of or lighter weights of Glass fibre or cheaper resins, we could even leave out the epoxy based skim coats and use car body filler instead.

We could, but we don't, your board and our reputation is worth more than that...

DIY Repair Materials  Board Repairs  DIY Board Repairs  Sail Repairs  DIY Sail Repairs  New Equipment  Sails  Masts   Booms   Neoprene   Harnesses   Casual Wear   Bags   Fins   Accessories   Nice Price   Sunscreens   Aqua Pro UK