Ok so I busted the nose off my sharpeye in the fun little windswell last Sunday (wasn't paying attention to how I drifted over a sand bar ). Now I have repaired a nose before, but this one is different. The top 8" of foam broke off cleanly, but it took some of the topsheet with it. The nose broke off and ripped a good 12" wide section of glass down the top of the board off with it. It ripped glass the glass parallel to the rails a good 2' down the center of the board (stringer is exposed). I've since cut the glass cleanly off the rest of the board. My question is how to approach the repair with regards to the glass. Should I:
1.) Cut the glasss of top of the broken nose, reattach nose, and then reglass the half the topsheet where foam is exposed (including the glass from the nose)?
2.) Reglass the top where it was ripped away, and then reattach nose in standard fashion?
cut all glass that is damaged, if it even looks damaged cut it, it is useless. reattach broken nose with clamps and cab/resin slurry, fill all damaged foam with resin slurry, 3 layers of 6 oz both sides at different length intervals, (first layer right on foam, second layers further towards glass, third layer at least 12" from any damaged glass, cut in v pattern or half moon pattern for strength. to spread load over larger surface area. glass layers with resin, feather in edges, hotcoat smooth. This is not the only way or even the right way to do it, it is how do it. i have never had a break come back. good luck and have fun.
#2 sounds like the best bet. No need to remove any glass that isn't de-lammed. If any of the foam came off when the glass came off the unbroken section... I would re-attach the nose. Put a layer of q-cell over the exposed area(s), sand back down to the level of the original glass (eversoslitghtly below). Glass entire nose overlapping q-cell area a good bit. 2 layers of 4oz should cover it. Make sure to stagger edge the top & bottom layers and make sure NOT to have the edge of the glass run perpindicular to the stringer as it creates a "breaking point/ seam". Sand/ blend edges, wax, & ride. =)
Thanks guys, both sound like good ways to proceed. A2tall one clarification, If I go with your method the first layer of glass should cover the entire area of exposed foam (2.5' x 1') and each following layer should be increasing larger than the previous layer? Do you think the weight of all this extra glass be an issue?