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Surboard Shapers Help!?

I am shaping a surfboard out of my dads 15 year old knee board. We stripped the fiberglass and resin and cut out the new shape with a stencil and it looks perfect. I’ve started to shape the rails and its been going well,but there is a soft patch near the rail where water could have leaked in. the board right now it is really thick and i’m gonna make it almost half the thickness will the soft patch be a problem thanks,

A picture would have helped, or if you at least told us how big the bad patch is. It may be a problem, but not one that is impossible to deal with. When I was a kid I skinned lots of boards and made blanks as out of surfboards that would be valuable classics today (dumb move, huh?). This should be easy, if you have enough foam left over from when you cut out your new template. Cut out the bad part, using nice square (90 degree) angles as much as you can. Cut a nice matching piece out of you left over foam, with it being a little larger than than your rail outline. It should fit it fairly snug. Mix some foam dust and some resin and lightly ‘glue’ it in place. When you are ready to sand your board, it should blend in fairly well. Depending on how you plan to do your finish glass coat, you may not be able to see this at all. Unless it is a big area (and at the very nose or tail) you won’t lose any structural integrity when its finished. Good luck. Let me know how you make out.
http://www.surfersteve.com/tips.htm

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