Recently my brother jumped back on a ‘fat boy’ board (5’6 x 19 x 2 3/8) I made for him about 4 years ago when he was over 180lbs (now less than 160). Anyway he’s been really ripping on it and catching everything in sight. He was bummed when he kicked out of a wave, the wind flipped it over and he landed on one of the fins. Thanks to UV cure and that I happened to have some Futures boxes in my shed (FGH closed on Sunday) I got him back in the water the next morning. Too bad I didn’t have a blue box to match.
Not saying this is the right way or the best way… this is how I did it in about 1.5 hours (not including the 3 hours I let the qcell mix harden), I used a rotozip free hand to cut the box out quickly rather than rout the box away with the install kit… a couple of 5oz dixie cups, some qcell, about 5oz UV lam resin, catalyst, surfacing agent, Futures install kit, angle finder, 3M 233+, a small piece of 4oz S-glass, single edge razor blade, 4 1/2 grinder with 50 grit, milwaukee 5540 w/ 6" med power pad, 150/220/320grits. a dollop of FGH polish. 3-4 minutes of afternoon Hawaiian sun. He could have surfed it the same day.