FCS Fusion plugs
FCS fusion plugs are a glass-over version of their fin plugs with a figure-eight form and wider footprint (see illustration).
Less resin is needed in the installation, which results in less exotherm and less thermal breakdown/foam-melting issues, particularly in temperature-sensitive EPS foam. The system is glassed-over on installation, so cracking around the plugs, which facilitates water seepage into the foam core, is prevented. Rather than two plugs, there is one single plug in a “figure eight” shape that sits in a high-density, waterproof foam, so if water somehow managed to seep into and around the edges of the plugs, leakage around the plugs and into the core of the board should be stopped by this layer. Finally, the slots for the fins are slightly longer than the tabs on the fins, providing fore-aft adjustability to tweak the performance of the fin-cluster.
 Originally designed for installation in EPS/Epoxy boards, FCS Fusion plugs are finding their way into Polyurethane boards as well.
While I have been informed that the system “tests” at similar numbers as the old two-plug system, I cannot help but feel the wider footprint and glassed-over nature of the Fusion plugs will stand up to stresses and stay stronger over time.
My take: A huge improvement over the old, two-plug system. The fins seem anchored very strongly in the plugs. The fore-aft adjustability is very useful in tweaking the ride; in the past I had boards with the RedX fin system and can testify that it is possible to radically alter the way a board performs by adjusting the position of the fins, and was even able to “save” a few poor-performing boards by=2 0changing the fin position.
That said, getting the fins mounted perfectly is a little tricky; the fins try to walk forward and backwards in the plugs as you cinch down on the grub screws, especially if the fins are brand new. A little tricky, but well-worth it to have the ability to change the position of the fins. The most recently-manufactured FCS fins now on the shelves have an oval-shaped recess in the fin tabs that should prevent this walking issue. If using a set of old fins, I have deduced a solution:
TIP: if using a set of the old-style fins and you want to get them in the standard/default center position, put them in a board with the old-style plugs and tighten the grub screws so as to etch the center of the fin tabs. When you put these “conditioned” fins into the Fusion plugs, the grub screw marks will guide the fins into the center position. If you want to take advantage of the fore-aft a djustability, I have found that setting your fins in the desired position and holding them firmly in place while tightening the screws down is tricky (maybe tighten and loosen them a few times to get that etch going), but easy once you get the feel of it. And no matter how tricky, the effect such adjustments have on performance are well-worth it.
Read on to hear about my stress-test of the plugs resulting from operator error:
I stupidly left the key in one of the plugs when I removed the old wax off the board today while it was lying on my  living room floor. Because the board was sliding all over the place, my knee, and my 180 lbs, was on the traction pad the whole time. The key got bent to hell (see pic), but the plugs are 100% fine (whew!). Kinda blows my mind that the thin part of the box near the grub screws did not crack under all that leverage and grinding, so I feel this is a testament to both the strength of the install as well as the strength of the material of which the plugs are made.
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