Surfboards are made from polyurethane or polystyrene foam blanks. The shaper designs the blanks and add the stringer(s). The blanks are laminated with a 4 to 6 ounce fiberglass cloth and covered with several coats of either polyester or epoxy resin to seal the foam and to give the board its strength. A sand coat is then added to ease sanding process. A clearcoat is sometimes added to give it a glossy shine. This is the simplified version of how surfboards are made. Manufacturers and shapers sometimes use other materials, processes and newer technologies to make their unique brand of surfboards.
Tuflites are epoxy surfboards from Surftech. Surftech uses polystyrene foam blanks which are three times lighter than polyurethane blanks. A PVC (poly vinyl chloride) is wrapped around the board followed by a 4 to 6 ounce fiberglass cloth. The sandwich is laminated and dipped with epoxy resin. The board is vacuum sealed and then sand coated. After the board is sanded, it is painted and oven cured to dry. A clear coat is added and polished to give it a polished and shiny look. Epoxyboards are usually lighter, stiffer and stronger than traditional polyester boards. The stiffness give surfers more responsiveness in the water while lighter weight allows for more radical air manuevers.
No matter how careful you are, surfboards will ding, crack or delaminate. If you cracked your epoxy surfboard, don’t despair. Get it fixed immediately before water seeps in and destroys it. You have two options: take it to your local surf shop or fix it yourself. Taking it to a shop will cost you a few hard earned dollars. Epoxy surfboard repair usually cost more to repair than most polyester boards. If the problem is minor, then you might be able to fix it yourself. Get an epoxy repair kit from a surf shop or a reputable source. Most epoxy kits today will dry clear compared to most marine products that dry to a brownish color.
Epoxy is an extremely tough and durable synthetic resin used for coatings. Epoxy is highly resistant to chemicals, abrasion, moisture and alcohol. Epoxy is not new to surfboards, epoxy boards have been around for decades. Lately, more and more shapers are using epoxy as prices of materials have drop and surfboard technology has improved.