The Art of Restoring a Vintage Surfboard

Restoring a surfboard is like bringing back a part of history, and involves a delicate balance of change and authenticity. It can be compared to the parable of Theseus’ Ship: a philosophical thought experiment that explores the nature of identity, and how we define the essence of something over time and change. 

This parable asks whether a ship if its parts are gradually replaced over time, remains the same ship. In the story, Theseus’ ship is kept in a museum, and as the wooden planks rot, they are replaced with new ones. Eventually, none of the original parts remain. This raises the question: is it still Theseus’ ship? And, if so, how can you replace so many parts while still maintaining an object’s original identity? 

The same question can be asked of surfboard restoration. When bringing a vintage board back to life, it’s not just about replacing materials—it’s about preserving the soul and essence of a timeless item. Restoration involves a delicate blend of craftsmanship, history, and passion, ultimately allowing the surfer to ride waves on a board that carries the legacy of decades past.

To get an inside look at the restoration process, we documented the restoration and revival of a Bonzer surfboard through the hard work and craftsmanship of Genaro Garro, owner and operator of Garro Surfboards here in Uvita, Costa Rica.  

The Differences Between Restoring, Repairing, and Making a Surfboard

Restoring a surfboard and making one from scratch are two distinct processes, though both require skill and an understanding of the craft. When making a new surfboard, the goal is to create something new and unique. The shaper and designer, in partnership with their client,  has full control over the shape, design, and materials. 

Restoration, on the other hand, requires respect for the original craftsmanship. The challenge lies in repairing the board while maintaining its authenticity. Vintage boards come with their own quirks, dings, and history. The goal of restoration is to make the board usable again while staying true to its original form. 

Repairing a surfboard, often called “ding repair,” is filling the cracks or dents of a surfboard without replacing any major elements unless the fins are also damaged. Ding repair often doesn’t entail changing the color, design, or key elements of the surfboard all at once. Dings happen all the time and don’t take nearly as long as restoring a board or making a board. 

Unlike making a new board, restoration demands that the surfboard shaper works within the boundaries of what already exists. This is why finding a skilled and experienced professional shaper like Genaro is critical to the process. For a closer look at how surfboards are made, check out our Bodhi Blog article here. 

The Difference Between Vintage Boards and Newer Boards

In recent years, vintage surfboards have made quite the comeback. Vintage surfboards, especially iconic models like the Bonzer, have unique characteristics that separate them from their modern counterparts. One major difference is the material. Many vintage boards were made with polyurethane foam and fiberglass, while modern boards often use epoxy or other lighter, more durable materials. Older boards were heavier, adding to their steadiness in the water but requiring more effort to maneuver.

Design is another distinguishing factor. Vintage surfboards, such as the Bonzer, were often designed with experimental shapes and fin setups. The Bonzer, for instance, features a unique multi-fin design that enhances speed and control, a unique feature not commonly found in standard thrusters or quads used today. 

Additionally, many older boards have more volume, allowing for a different paddling experience compared to the streamlined designs of today’s performance-oriented surfboards. Despite the many advances in surfboard technology, vintage surfboards are becoming more popular and more recognized. The value of older surfboards lies in the history behind the surfboard. This nostalgia is pushing for a higher demand in surfboard restoration, where the “retro” quirks and flaws are becoming more and more appreciated by surfers and surfboard enthusiasts alike. 

Common Wear and Tear of an Older Surfboard

When restoring a vintage surfboard, the first step is a thorough visual inspection of the state of the surfboard. Years of exposure to the elements and the stress of riding waves will inevitably cause any surfboard to suffer from some wear and tear. Understanding the common types of wear and tear is crucial for determining how to approach the restoration process.

One of the most common issues with older surfboards is delamination, where the fiberglass layer begins to separate from the foam core. This can occur from sun exposure or moisture getting into the board, causing the materials to weaken. Delamination typically initially appears as bubbles or soft spots on the surface of the board. 

Dings, cracks, and dents are also common in vintage boards. These typically occur from contact with rocks, reefs, or general use. While minor dings might just be cosmetic, deep cracks can affect the structural integrity of the board, especially around critical areas like the nose, rails, and tail. Prolonged exposure to the sun is the kryptonite to all surfboards. Over time, sun damage can cause discoloration and weaken the materials. 

Water damage is another concern for older boards. If a ding or crack isn’t properly sealed, water can seep into the foam core, leading to soft spots or even rot. It’s important to identify any areas where water might have gotten through and assess the damage before proceeding with repairs. So, it’s very important (not just for surfboard restoration) to know how to protect your surfboard from damage. 

The Bonzer SDKT Surfboard Model 

Below are the photos of the original version of the surfboard (before restoration) from the front and the back:

The Bonzer surfboard, invented by brothers Malcolm and Duncan Campbell in the early 1970s, shook the surfing world with its unique design. In fact, the Campbell brothers’ design has become an important part of the history of surfboard design. The SDKT (Standard Double Keel Twin) Bonzer model reflects more than 50 years of some pretty intense work. In 1970, the three fin Bonzer was completely revolutionary. Those who have ridden this particular model can attest to the endless possibilities it presents while riding waves. 

The true beauty of the bonzer mechanics lies in the rail design, fin design, and how both compliment each other so well by greatly reducing drag and resistance. The fins stabilize the board while allowing for tighter turns, giving riders more control in the pocket of the wave. Bonzers also excel in a variety of wave conditions, making them versatile for both small and powerful surf. 

Tools and Materials Needed for Restoration

Restoring a vintage surfboard requires both basic tools and specialized equipment, particularly when working on something as unique as a Bonzer. Here’s a rundown of what you’ll need:

Basic tools:

1. Sandpaper (various grits) and sanding block: Used to smooth out dings, cracks, and repair areas.
2. Power sander: For more extensive sanding needs, particularly when dealing with larger delamination spots.
3. Masking tape: Essential for taping off areas you don’t want to affect during the repair process.
4. Razor blade: Helpful for precise cutting, such as trimming fiberglass cloth.
5. Respirator mask and gloves: Safety first—resins and sanding dust can be harmful to the lungs and skin.

Materials:

1. Fiberglass cloth: Essential for patching delaminated sections or larger cracks.
2. Resin (polyester or epoxy, depending on the original board material): The adhesive that binds the fiberglass and seals the repairs.
3. Surfboard filler: A putty used for filling small dents and cracks.
4. Fin box replacement materials: In case the Bonzer’s unique fin setup has been damaged.
5. Pigment: If you need to color-match the repair to the original board.
6. Paper: protects the areas that are not getting painted.

Repairing the Board

For this particular restoration project, the process was very involved and challenging. First, Genaro began by gently sanding around the delaminated area.Once the dust was removed, he added the filler. What the filler did was replace the foam if any pieces were to come out. It was left for a couple of days, in case of water damage, to fully dry out before proceeding. Next, after sanding over everything that was filled, he added the fiberglass to the board. 

When fiberglass is added to a surfboard during restoration, it transforms the repair process by reinforcing the structure and creating a smooth, durable surface. After prepping the damaged area—sanding and cleaning— he cut fiberglass cloth to fit the repair site. Once the resin was mixed, it was applied to the fiberglass cloth. As the cloth got saturated with resin, it became translucent, bonding to the board’s surface.

The resin has to harden as it cures, forming a tough, protective shell. During this phase, it’s crucial to eliminate air bubbles and ensure the fiberglass lies flat, maintaining the board’s original shape.

Below is a timelapse video of some of these important steps in the repair of the board:

Patience is key in any repair process. Rushing can result in imperfections or weakened repairs. For example, the resin curing fully before sanding or reapplying is crucial for achieving a strong, long-lasting repair. This is exactly why an experienced professional like Genaro is necessary to ensure a surfboard is properly restored. 

Restoring the fins and bottom contours is another tricky part of restoring this particular model of surfboard. The fins and bottom contours are what make the Bonzer such a unique ride. In this case, the original fins of the surfboard were preserved, which allows for some real authenticity of the Bonzer surfboard experience.

When restoring a vintage surfboard like the Bonzer, maintaining its aesthetic appeal is just as important as repairing its structural integrity. This step ensures that the board looks as good as it rides, preserving its visual identity and heritage.

One of the most iconic features of any surfboard is its logo. Vintage Bonzers often have the classic Bonzer emblem, which reflects the board’s authenticity and ties it to its creators, the Campbell brothers. In this case, the logo was designed in homage to the original by a friend and colleague of the owner of the surfboard. 

Here are photos of the final result, from back to front:

Why Restore a Surfboard Instead of Buying New?

Restoring any surfboard is more than just a technical task—it’s a journey that blends craftsmanship, patience, and a deep respect for surfing history. The joy comes not only from seeing an older board transformed into something beautiful and functional again but also from the knowledge that you’ve given a piece of surfing culture a second chance to ride the waves. 

The restoration process connects the owner and the shaper to the board’s origins, allowing the owner of this board to experience the story and history passed down through the generations.  Restoring a vintage surfboard isn’t always about practicality—it’s about preserving history, honing a craft, and connecting with the past. Modern boards, while technologically advanced, often lack the character and individuality found in vintage models like the Bonzer. 

Restoration is an art form. Each step—as exemplified by Genaro’s attention and mastery of detail—is a way of breathing life back into something with a history. It’s a process that demands patience and passion. The end result is more than just a surfboard; it’s a connection to the past. Every restored board has a story to tell, and by taking on such a project, you become a part of that story.

Restoring a surfboard is also a more environmentally friendly option than making a new one, because it reduces waste and the need for new materials. By restoring an old board, you are keeping it out of landfills and minimizing the demand for raw materials. 

Additionally, restoration consumes fewer resources and energy compared to creating a new board from scratch. It’s a sustainable practice that preserves both the surfboard’s legacy and the planet’s well-being. Here at Bodhi, we are all about environmental impact reduction, and we support anything that is good for mother earth. 

Restoring a vintage surfboard like the Bonzer was a deeply gratifying experience to be a part of. It’s about so much more than just getting a board back in the water. It’s about respecting the surf culture, and honoring the craft and artistry of surfboard restoration. We highly recommend reusing and restoring an older board-and giving a part of surf history a chance to come back to life.