Secret Technique Revealed: Repairing a Carbon Foil Mast Like a Pro!

**Also Watch How To Repair A Foil Box**:

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In this video, we tackle a common issue faced by foil riders: damage to the carbon foil mast caused by hitting a rock on the bottom. This specific repair involves the back blade of the mast, which can be critically compromised during such accidents, especially when riding in shallow reef areas. Damaged carbon parts are not only hazardous due to their razor-sharp edges but also pose a significant risk of sudden failure.

Join us as we reveal a secret technique to effectively repair your carbon foil mast. We’ll walk you through every crucial step, from the initial damage assessment to the final polishing, ensuring your mast is as good as new.

Step 1: Assessing the Damage
We begin by examining the extent of the damage to the back blade of the mast. Understanding the severity of the damage is vital for planning the repair.

Step 2: Preparing the Damaged Part
Using a rotary tool and sandpaper, we carefully remove the damaged carbon. This preparation is critical for the success of the repair, as it ensures a clean and smooth surface for the new carbon layers to adhere to.

Step 3: Creating the Mold
To restore the original shape of the mast, we first layer some tape over the damaged area. Then, we press a 2K putty over the first side using a thin piece of wood to create the first half of the mold. After flipping the mast and applying a release agent to prevent sticking, we repeat the putty pressing procedure on the other side to complete the mold.

Step 4: Preparing Carbon Strips
Using Kevlar scissors, we precisely cut 4K carbon strips, ready to be glassed. Precision in this step is key to ensure a perfect fit.

Step 5: Saturating the Carbon Cloth
We saturate the carbon cloth over the prepared damaged part with epoxy resin, one side at a time. To prevent resin drips, we add a superficial layer of fiberglass on each side. The two carbon layers then stick together to form a flange, effectively restoring the blade at the back of the mast.

Step 6: Clamping the Mold
Positioning the two halves of the mold, we press them together with two clamps, allowing the excess resin to escape. This step is crucial to ensure the carbon cloth has minimal resin, resulting in a super stiff and durable composite.

Step 7: Final Sanding and Shaping
Once the epoxy resin has cured, we open the clamps and begin sanding with a professional sander to restore the mast’s desired shape. The surface will be rough at this stage, so we hotcoat the part with epoxy resin and fine sand it after curing.

Step 8: Polishing to a Matte Finish
For the final touch, we use a high-cut polishing compound to achieve a smooth, matte finish, ensuring the repaired area blends seamlessly with the rest of the mast.

By following these detailed steps, you can confidently repair your carbon foil mast, restoring its integrity and performance. Don't forget to like, comment, and subscribe for more repair tutorials and tips!