26 modification - installing foil box

Install the box in the board

1. Remove foot pads.

2. Mark the location where to install the new box.

3. Use a jig saw to cut a a hole for the box.

4. Fit the box to the hole - the box should fit the hole as tightly as possible.

5. Trim the top of the box flush with the deck. (A hack saw or dremmel works well to cut the bolt cups).

6. Tape a piece of wood over the box to keep it in place while it is being glued in the next step.

7. The bottom of the box should be flush with the bottom of the board. Insert a fin to make sure that the box is square, use shims if necessary. Use gorilla glue to glue in the box.

8. When the glue is dry, trim/sand off the excess glue, remove the tape.

Finish the area

1. Sand the area around the box through to the underlying fiber glass.

2. Laminate over the box using one layer of 4oz fiber glass cloth (the weave is small enough to prevent epoxy from dripping through into the box) and 3-4 layers of carbon fiber cloth, and a final layer of 4oz cloth (this final "sacrificial" layer helps when sanding flat so you are not sanding through the carbon fiber).

3. Cover with peel ply (or plastic) for smooth finish.

4. Remove peel ply, sand the area with palm sander.

5. Add a layer of hotcoat, two coats if necessary, sanding between coats. Sand smooth to finish. Tint the epoxy with colored pigment or paint when fully cured if necessary.

6. Open the fin slot by drilling a pilot hole, then using a router with a Bevel Trim Bit.

7. Repeat the above steps to finish the deck of the board. (I used 3 layers of carbon fiber on the deck). Use the router to open the bolt cups.

8. Paint the foil box and deck area.

9. Replace the foot pads using contact cement to glue them back down.

10. If necessary, add non-skid to any areas by rolling on a thin layer of epoxy and then dusting with non-skid powder.