So I was installing FCS fusion plugs on my eps blank, and apparently didnt measue the resin right. I thought that i had mixed it at a 2(resin)-1(hardner) ratio, with RR epoxy. Anyways, the epoxy got too hot and it melted through the blank. I cut out the hollow spots and wasnt sure what i was going to do...I was thinking of cutting a piece of foam and placing it over the hole, then gluing it in and then sealing and glassing as normal, but i am not sure how strong this will be. Any better ideas???? Any help would be much appreciated.
You probably got the measurements exactly right. Epoxy does that.
Figure out a template that will go around your meltouts. Rerout using the new template and cut some high density foam or balsa blocks to fit the new holes. Now rerout and insert your plugs and pretend you planned it that way. With light foams it's sometimes necessary. When adding resin to the plugs, do it in stages so you don't have a large amount of resin exotherming to the point your foam melts.
Do you have a pro router jig set up or did you just make some holes that the boxes would fit into ? Close tolerance is important, even for polyester.
The old FCS, because they use a LOT of resin, I learned to 2 stage those, but Lokbox , Future, Pro Box and I assume the Fusion system, are tight fit and don’t use much resin. I have NOT melted any other EPS blanks besides using FCS plugs and a full pour
I aways keep a few of those instant ice packs around when I'm pouring fin holes in eps. Epoxy therms fast in thick batches. So if it's a hot day, and I'm doing all 3 or 4 fins at once I'll crack a few instant ice packs and put them under the board. After 15 or 20 mins the risk of therm blow out has passed and your good to go.
Target sells ACE instant packs for 99 cents in the travel size section. Just another 3M product to simplify your life...and reduce future stress.
If your too cheep for instant cold packs, a ziplock bag with ice works too....but ice sweats in ziplocks.
Did you use fast or slow hardner? I use slow to extend the time of the exotherm, you know, mcdeltaT. The ice pack thing is good also. The last compsand I just finished in my garage was done after work at 8pm or so and the temperature averaged 88-96 degrees F. Unfortunately, I had a few sweat pool dribbles into the lam, but my fcs fusion boxes came out pretty good.
