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Repairing FCS Fin Plugs

FCS Surfboard Fin Plug Repair

The Fin Control System® is designed with safety in mind, in most cases a collision between your surfboard and body can result in damage to your surfboard and sometimes injury to yourself.

Using the Fin Control System the chances of this happening are reduced. The fin has tabs that are engineered to break off in most collisions, therefore, causing no damage to the surfboard and reducing the chances of injury.

If this occurs, undo grub screws, turn the surfboard upside down and lightly tap over the broken fin – the tabs will fall out – (a freeing agent can be used), then simply replace the fin and go surfing!

If, however, there is damage to your Fin Control Plug in the surfboard, follow these steps.

  1. Gather your materials and tools: 1 1/8”(30mm) holesaw, drill, resin and hardener,fiberglass powder,replacement FCS plug, repair jig (this can be made out of a 2“x4” piece of 1/2” plywood), spare FCS fin,and tape.

  2. Make repair jig by drilling 1 1/8” hole through the center of the 1/2” plywood. This will be used to keep the hole saw straight while drilling out the damaged plug.

  3. Center and tape fin jig over damaged Fin Control Plug. (Picture #1, Jig is aluminum)

  4. Mark hole saw with tape to measure 3/4 inch deep. Drill with hole saw to correct depth, (hole saw should be cutting resin around the Fin Control Plug). (Picture #2)

  5. Remove hole saw and drilling jig, then with a screwdriver in the Fin Control Plug slot, wiggle the plug until it cracks away from the resin and then remove. (Picture #3) 

  6. Install the new Fin Control Plug on the tab of a fin and tighten. (Don’t forget to clean the plugs with acetone before installation). Insert into hole and second plug. Make sure the plug stoppers are flush with the bottom of the board. 

  7. If repair hole is very large, first fill cavity with Q-CELL/resin and sand flat. Note: Do not let Q-CELL/resin set for a long time before refitting the Fin Control Plug. This will ensure that the boring of the hole with Q-CELL/resin is not to difficult.

  8. Tape off area around the plug.

  9. Mix up a enough resin to fill in around the plug. Add some milled or chopped fiberglass to the resin along with hardener. (Do not use Q-CELL filler for this – it’s too weak.) Using a squeeze bottle or small pouring cup, add the resin into the area around the plug. (Make sure not to drip any resin into the top of the plug.) 

  10. Let the plug harden and then remove the spare fin jig. Turn the screw so it is below the surface of the plug and begin sanding. Use 60 -80 grit to take down the rough part then continue with finer grits.

Repair cracks around Fin Control Plugs in the same manner, but if the crack is very small, scratch up with a sharp instrument and fill with Q-CELL/resin.