Wow! Great responses.

Jake, the failures are caused by flexing. It's usually at the bend between the horizontal foot and vertical leg sections.

dacarls, I know some surf guys who may be able to hook me up with a shaper. Science is still taught in the Maui schools. Our closest is Lahainaluna. I'll nose around and see what I can turn up. I'll also pass your suggestions on materials to the doc.