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Windsurfing workshopHow to repair carbon forks

Manuel Vogel

 · 25.04.2022

Windsurfing workshop: How to repair carbon forksPhoto: Manuel Vogel
Workshop: How to repair your carbon fork
Carbon forks are capable of suffering - they usually survive hard landings, skidding crashes and the eternal chop much longer than aluminium forks. Only the connection between the bars and the front end suffers noticeably at some point. We'll show you how to alleviate this suffering in the workshop!

They cannot bend, are stiff and therefore allow the entire adjustment range to be used - the arguments for buying carbon forks are compelling. Anyone who surfs a lot in the waves, is on the regatta course or regularly bends aluminium forks due to a higher body weight will not necessarily ride more expensively with carbon forks. Only the connection between the screwed-on front piece and the carbon spars will eventually become loose over time. If you just keep on surfing, you run the risk of weakening the material at this point and breaking the bars at the head piece.

Carbon forks - Refresh in 30 minutes

With just 30 minutes' work and a few euros' worth of repair materials, this problem can be fixed permanently. Oli Schott, long-time participant in the German Windsurf Cup and absolute repair professional, shows you the most important steps below. Because the majority of boom models are produced by Aeron and the components are often the same across brands, the following repair tips are therefore valid for many products.

You will need the following items to repair your carbon forks:

  • Screwdriver & Allen key
  • Hammer
  • Scissors or cutter knife
  • Some masking tape
  • Plastic film Walopur 4201 AU
Repair professional Oli Schott gained his expertise as a rider in the German Windsurf Cup.Photo: Manuel VogelRepair professional Oli Schott gained his expertise as a rider in the German Windsurf Cup.

Step 1: Remove the front piece

If you notice that the front piece is sliding back and forth on the spar or starting to wobble ...Fig. 1:Photo: Manuel VogelIf you notice that the front piece is sliding back and forth on the spar or starting to wobble ...Fig. 1:... you should start with the repair as soon as possible. The front piece is usually only screwed onto the continuous bar. The nuts can be loosened and the two metal bolts removed using a suitable Allen key or Phillips screwdriver.Photo: Manuel Vogel... you should start with the repair as soon as possible. The front piece is usually only screwed onto the continuous bar. The nuts can be loosened and the two metal bolts removed using a suitable Allen key or Phillips screwdriver.Once these have been removed, you can detach the individual parts such as the quick-release fastener and mast mount from the spar.Photo: Manuel VogelOnce these have been removed, you can detach the individual parts such as the quick-release fastener and mast mount from the spar.The bolts are often no longer completely straight and must be straightened before installation.Photo: Manuel VogelThe bolts are often no longer completely straight and must be straightened before installation.On the bare spar you can also see the marks left by the bottom sleeve of the front piece due to the constant vibrations on the spar.Photo: Manuel VogelOn the bare spar you can also see the marks left by the bottom sleeve of the front piece due to the constant vibrations on the spar.

Step 2: New support for the front piece

To be able to reinstall the metal bolts later, Oli straightens them first. Insert the screws into the bolts, place them on a hard surface and carefully tap them straight again with a hammer.Photo: Manuel VogelTo be able to reinstall the metal bolts later, Oli straightens them first. Insert the screws into the bolts, place them on a hard surface and carefully tap them straight again with a hammer.Oli's secret tip for a tight fit of the headpiece is a synthetic rubber, which he places between the front piece and the spars. Normal tape or conventional rubbers would quickly grind down and the wobbling would return. Oli recommends a material, "Walopur 4201 AU", which is also used for kite tubes and is very resistant. This is only available to wholesalers, but Oli offers inexpensive repair kits with material for two forks for 17.50 euros via <a href="http://repairkit@pesunlimited.de/" target="_blank" rel="noopener noreferrer nofollow">repairkit@pesunlimited.de</a>. Alternatively, you can ask for old kite tubes at Sail & Kite Repair.Photo: Manuel VogelOli's secret tip for a tight fit of the headpiece is a synthetic rubber, which he places between the front piece and the spars. Normal tape or conventional rubbers would quickly grind down and the wobbling would return. Oli recommends a material, "Walopur 4201 AU", which is also used for kite tubes and is very resistant. This is only available to wholesalers, but Oli offers inexpensive repair kits with material for two forks for 17.50 euros via repairkit@pesunlimited.de. Alternatively, you can ask for old kite tubes at Sail & Kite Repair.Cut a piece out of the rubber that is slightly wider than the bottom cuff of the front piece.Photo: Manuel VogelCut a piece out of the rubber that is slightly wider than the bottom cuff of the front piece.
Wrap this piece of rubber around the spar two to three times (depending on the amount of play).Photo: Manuel VogelWrap this piece of rubber around the spar two to three times (depending on the amount of play).Pull it tight and secure the rubber with a strip of Tesa masking tape.Photo: Manuel VogelPull it tight and secure the rubber with a strip of Tesa masking tape.Then start fitting the front piece and insert the first sleeve first.Photo: Manuel VogelThen start fitting the front piece and insert the first sleeve first.Then click on the mast mount.Photo: Manuel VogelThen click on the mast mount.You can only see whether you have wound the rubber thick enough when the bolts are screwed back together.Photo: Manuel VogelYou can only see whether you have wound the rubber thick enough when the bolts are screwed back together.

You can repeat the repair described above at any time if the front section develops some play again over time. This way you can use your carbon forks for a long time.

Tip:You can find many more workshops and do-it-yourself topics regularly in the print and digital editions of surf. With our favourable subscription offers, you are guaranteed never to miss an issue. Click here!

The SURF 9/2019 issuePhoto: Stephan GölnitzThe SURF 9/2019 issue
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