FCS Fusion Stress Crack - help

Hey guys!

I’ve ran into a problem which i dont know how to approach.  I’ve searched around and havent quite found a definitive solution.  I usually fix my own dings, being that they are quite minor, but repairs dealing with fin boxes are beyond me.  I noticed this stress crack on the toe side fin box after a couple sessions on the board and im sure it’s the reason why my board has been acting weird.  Sometimes while pumping down the line, the board just slows down quite abruplty out of nowhere.  The first time this happened, i looked backed to see if i snagged something in my leash.  This doesnt happen on every wave, but it happens enough during a session to really bug me.  I’ve since sidelined the board until i’ve figured out my options.

The crack appears to be quite deep and i can feel its edge when i run my finger nail perpendicular.  Though the box still feels strong when i tug the fin side to side, i feel a degree of the boxes strength has been compromised.  So my question is, what would you guys recommend doing?  Can i put some patches over the box to reinforce it or should i get the box replaced?  If it must be the latter, i’d definitely have to take it in somwhere being that i dont have the tools for that kind of job.  Any suggestions will be appreciated.  mahalo.

[img_assist|nid=1065675|title=FCS Fusion Stress Crack|desc=|link=none|align=left|width=640|height=352]

looks from the picture like the glass overtop of the box delaminated from the box in that one area…if this is true, then chances are the bubble is gonna spread… just fix it now.

take out the screws, and route the box out…replace it…glass over, and you’re good 

if there is any movement in the box when the fin is attached and your putting some pressure on it side to side then i would replace the box as astevens said

if there is no movement then i would just grind down those crack and reglass

I use fusions on most of my boards. They are really tight and surprisingly strong. When they do let go you will have very little doubt that the box is compromised. That glass job over the box looks pretty thin to me; like they did the bottom lam without football patches or a tail patch. Fusions get their strength from being tight and having a good patch over top of them to distribute the stress when the fin is under pressure.

But like SD said if it’s still tight then you are good. Bury the screws into the box and grind off the delam and reglass, fill coat, sand. the slots in fusions are raised so they can be sanded off, now that yours are flush you need to build up the stickers or tape over the slots so you can have a high spot to hit with the sander or grinder to re-expose the slots and screw holes.  If you really love this board and aren’t good with these kinds of repairs take it to your local repair guy…pretty easy repair for one of those guys. Too bad you’re not close to SD! He has rebuilt total wrecks!

If it was my board I might go a little further and add a 4 oz patch over the whole tail area to add strength to all the boxes, you might be getting too much flex in the boxes due to a lightweight bottom lam; thus cracking at the lam over the fusions. It would add a few ounces to the weight of the board but I think it would be worth it.  My 2 cents.

Woody

Thanks for the quick responses!

The boxes are still pretty tight and there doesnt seem to be any movement.  

Thanks Woody, looks like im going to follow your suggestion with this one.  Mahalo.

kohola,

 Be careful not to grind into the foam. I say this because the top of the fusion box is slightly below the foam, so you will most likely hit foam befor you hit the box when grinding. also, another reason why I would re route the fusion box is because it would be easier for me to glass over the fin tab holes and screw holes with the raised rim of a new fusion plug and some stickers. just what I would do personally if someone handed me this thing, but I guess it can be done many different ways… good luck, adam

ahh, I see what you mean about the tab holes.  well, I havent done the deed yet, and getting a new box dropped in is starting to look like a better idea.

Would anyone recommend a good shop/person to drop my board off to on Oahu?