Epoxyboard Anatomy
Water in Board
Repairs - Menu
Assorted Repairs
Ancient History
Legal Stuff
No-Vacuum Divinycell  
As much as I normally advocate the use of vacuum to affix anything related to sheet goods, there are times when a few bits of tape do just as well - just as reliably, just as free from voids: when the ding in question is located on the curvaceous portion of a rail. In that case, and that case only, the pressure generated by such tape is adequate to ensure a perfect bond.

A typical mishap with a pointy, hard object.

Besides the obvious dent, the Divinycell turns out to have internal fractures. At this juncture, the bond of inner glass to Divinycell as well as to EPS must be questioned. No point to rebuild without removing everything that is at all suspicious!!
Everything loose is removed, and the edges beveled
A new piece of PVC sheet foam is cut (this is Herex, chemically and mechanically same as Divinycell, just different color), marked as to location and orientation, warmed with a heat gun, quickly slapped onto the beveled repair area, pressed in place and held there until it cools. While there is a little spring-back, the PVC generally holds this shape.

Do not pursue the brilliant idea to form the PVC in place - the heat would melt away all the EPS in the vicinity!!

The formed bit of PVC, as well as the beveled repair area are laminated with one each layer of 4oz cloth in Epoxy (with the very slow hardner!).
and assembled.
starting in the middle, and exerting considerable pressure, masking tape is affixed, working towards the edges, dabbing up the Epoxy as it squeezes out.

Let cure completely.

remove tape, sand away excess, and find a perfect scarph-joint, with the edges of the inner glass visible all around its perimeter.

From here, glass and refinish like you would a simple surface ding!

return to Repair Menu