How to Cut a Surfboard That Has Already Been Glassed

One of the main reasons for cutting a surfboard is to repair surface damage or dings. Surfboards have three main components: a foam core, a fiberglass covering and a resin to bind them together. Use a surfboard long enough and it will need to be repaired or altered. Cutting a finished surfboard is easy to do, but repairing it can be tricky. Cutting into the fiberglass will break the waterproof seal around the foam, requiring a new coating of fiberglass and resin to protect the surfboard core from water damage. Unless you're a skilled professional, cutting and repairing a finished surfboard will create a noticeable patch, but is much cheaper than buying a new board.

Things You'll Need

  • razor blade
  • scissors
  • surfboard repair kit
  • tape
  • sandpaper
  • Popsicle stick
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Instructions

    • 1

      Cut around the damaged area with a razor blade, box cutter or very sharp pen knife. Be sure to completely cut around the entire ding, or anywhere the fiberglass has pulled away from the foam. If the foam underneath is wet, allow to completely dry before beginning any repair work.

    • 2

      Sand the damaged area with a rough-grit sandpaper to allow a surface for the repair resin to adhere. Be sure to sand the fiberglass around the foam to ensure the patch forms a water tight seal.

    • 3

      Tape the area off around the damage to prevent excessive clean up later on. Cut a patch cloth to size from the surfboard repair kit and set aside. Cut the patch in a circular or oval shape to prevent corners from peeling up down the road.

    • 4

      Mix the resin and hardener and apply a thin coat to the damaged area. Press the patch onto the ding and cover with a thick coat of mixed resin. Be sure to completely cover the patch fibers with mixed resin. Work quickly as the mixed resin begins drying within minutes. For extra strength, repeat the process with another patch while the mixed resin is still wet. Allow to dry overnight.

    • 5

      With a fine-grit sandpaper, sand the resin smooth. Wet the sandpaper with water for a glossy finish. Take care when sanding so you do not expose the patch fibers.