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Fitting FCS Fusion Plugs

September 8, 2017 / Murray Steward

How to fit FCS Fusion Plugs.

You’ will have chosen your preferred fin system. We still prefer the original FCS system above Futures and fit it as standard, but FCS II is gaining in popularity, and Fusion of course is the choice for EPS/Epoxy boards. Here is the definitive video on Fusion Box fitment. We hope to get a better video soon. In the meantime, here is our useful guide to help you along.

We’ve combined all three FCS systems – the method is similar, you just need a variety of different tools. Seabase has a Fin Fitment Loan Scheme – enquire for details. (All you need for one week’s loan – deposit required, terms apply.)

FCS Fusion Boxes:

Choose FCS Fusion Originals for EPS boards. Not suitable in PU blanks. Decide the angle of your fin setup – 5° or 9° offset.  You need 2 x side plugs and 1 x centre plug for a thruster setup, 2 side plugs for a twin. (Suggest ) For a quad surfboard 4 side plugs. For a five fin 4 side plugs (suggest ) and 1 x centre plug. FCS Fusion plugs are added before laminating the board. Measure and mark the plug centres. Drill according to instructions in this video. Fit carefully, sand and seal. (You should seal the fitting to prevent any water ingress. Use a good speedcote around the area).

Go here for instructions on FCS Original Plugs, FCS X2 Plugs, and FCS II plugs.

Using resins:

Fusion Plugs (boxes) are for use in PU or EPS foam, and are fitted using Epoxy Resin. Use the recommended Fibreglass Filler Powder; the reinforcement it offers increases water resistance and resists cracking.  Do not use Polyester Resin in EPS foam. Epoxy Resin is ideal for either PU or EPS foam. If using Epoxy Resin – especially for FCS II or Fusion in EPS foam – use Resin Research 200CE with the standard 2100F hardener. Do not necessarily, use a slow hardener UNLESS you have a deep hole to fill. Slow hardeners may drain too easily, and cause voids that require refilling.  In nearly every case, we use the Resin Research 2100F fast hardener. (2100S and 2100X hardeners are used for concentrates of resin, where a fast hardener cause a high temperature en masse, and may crack or craze as a result). Adding Fumed Silica in small quantities to the mix (after catalyst or hardener is added) aids sanding and reduces drainage. FCS recommend the use of their fibreglass powder for a solid, strong fitment. Use it.