I recently acquired an old F2 Lightning World Cup that was in good condition other than a bodgy foot plug repair.







About 6mm layer of chop strand and polyester had been used to build up the surface. Yes the purchace did involve some risk because we all know about polyester and white foam boards!

I've ground off the chop strand and got back to the basic board. What I have now is an obvious cavity and a loose foot plug. I've ground off the plastic f2 coating and exposed the epoxy fibreglass that the board is made of. This is what I was expecting as I had repaired a deck on a similar F2 Lightning.

Here's a video



What I was thinking was back fill the cavity with 2 part pour in place foam let it set and then sand to surface height.

Dig out a foot plug insert shaped hole. Wrapp the insert in cloth and epoxy before inserting and setting. Then re-building up the deck with some layers of 200gsm cloth and epoxy.

Over doing it / undergoing it? I think the hole may be too big just to backfill with epoxy and micro balloons? Worried about ectothermic with that approach

Ideas appreciated - looking for stable repair but want to go sailing next week

Cheers Jeff
Foot plug insert had a wrap of 3mm high
density foam around the insert pocket. With F2 the insert socket is moulded in during construction and the plug then inserted



Cheers again....
Working to the closest cm