How to Fix EPS Epoxy Surfboard

At Boat Suppliers, we’re excited to introduce our new line of starter kits—designed to make composite repairs simple and effective. Today, we're walking you through a real-world repair using our EPS Epoxy Surfboard Repair Kit. Whether you're patching up a dinged surfboard or restoring an eFoil, this step-by-step guide will show you how to get pro-level results.

🛠️ Project: eFoil Repair on EPS Construction

This tutorial features an electric eFoil with an EPS (expanded polystyrene) core and fiberglass shell. Let’s get started.

Step 1: Prep the Damaged Area

• Remove loose debris and any broken fiberglass.
• Sand down the edges of the damaged area to create a smooth transition for the new fiberglass to bond to the old.
• For deeper repairs, use the EPS foam block included in the kit to fill large voids. This minimizes epoxy use and maintains structural integrity.
  

Step 2: Seal the Foam Core

• Apply a thin seal coat of epoxy directly over the exposed foam. This protects it from over-saturation and preps the surface for bonding.

Step 3: Build the Shape with Q-Cell Filler

• Mix q-cell filler with epoxy to create a thick paste.
• Fill in the damaged area, shaping it as close to the original contour as possible.
• Let it cure, then sand smooth.
  

Step 4: Fine Tune with Fairing Compound

• Inspect for any air bubbles or low spots.
• Use the epoxy fairing compound (also included in the kit) to touch up imperfections.
• Sand again, then wipe clean with alcohol to remove any dust or residue.
  

Step 5: Apply Fiberglass Layers

• Cut two fiberglass cloth patches:
  • One slightly smaller than the repair zone (base layer)
  • One larger, overlapping the existing fiberglass (top layer)
    
• Mix fresh epoxy resin (no fillers).
• Apply both layers wet-on-wet, saturating the cloth completely.
• Allow the resin to fully cure before moving to the next step.
  

Step 6: Sand and Feather the Edges

• Once cured, sand down the fiberglass patch, carefully feathering the edges into the surrounding board.
• Avoid sanding through the new fiberglass—just smooth and blend.
  

Step 7: Finish with a Hot Coat

• Mix a clean batch of epoxy resin, no fillers.
• Apply a final hot coat over the repair area to seal everything in.
• After curing, you can:
  • Sand and paint, or
  • Apply a decal or sticker to match the board’s look.
    

You're Done!

Your EPS surfboard or eFoil is now watertight, reinforced, and ready to ride. This entire process is made simple with the EPS Epoxy Repair Kit from Boat Suppliers—built for durability and ease of use.

If you have questions or need more help, don’t hesitate to reach out to our support team.

✅ Shop the EPS Epoxy Repair Kit
🔧 Need Help? Contact Us Anytime
📦 Fast Shipping. Pro-Quality Materials.