PACESHIP CRUISING YACHT Maintenance Manual - page 12

REPAIR OF FIBERGLASS GELCOAT

The repair of gelcoat is easy because only the surface of the boat is damaged. This is similar to a scratch

in automobile paint. The damage falls into two categories:

(1) Damage to the gelcoat colored outer surface.

(2) Holes or gouges that are deep enough to penetrate the fiberglass reinforced areas of the boat. The

repair operations are similar.

For damage to the gelcoat surface, you require: (1) A small can of gelcoat (the same color as your boat)

and (2) a small amount of catalyst. For deeper holes or gouges (½” or more), you will also require short

strands of fiberglass, which can be trimmed from fiberglass mat or purchased in the form of milled fibres.

1. Make sure the area around the damaged area is wiped clean and is dry. Remove any wax or oil from

the Inside of the hole or scratch (acetone can be used for this purpose).

2. Use a power drill with a burr attachment, to roughen the bottom and sides of the damaged area and

feather the edge surrounding the scratch or gouge. If a burr is not available, a putty knife and 400 grit

sandpaper can be used.

3. Pour a small amount of gelcoat into a jar lid or on cardboard. Add a drop or two of catalyst. Mix

thoroughly, using a cutting motion, rather than stirring. USE NO

FIBRES.

4. Using your finger or the tip of a putty knife, fill the hole with the gelcoat mixture, about 1/16” above the

surrounding surface.

5. Lay a piece of cellophane or waxed paper over the repair to cut off the air and start the cure.

6. After 10 or 15 minutes, the patch will be partially cured (70 degrees F.) When it feels rubbery to the

touch, remove the cellophane and trim flush with the surface. Use a sharp razor blade or putty knife.

Replace the cellophane and allow to cure completely (30 min. - 1 hr.). The patch will shrink slightly below

the surface as it cures.

7. Sand the patched area with 600 grit wet sandpaper. Finish by rubbing or buffing with fine rubbing

compound. Slight color difference may be observed but weathering will blend this touch-up, if properly

applied.

FOR HOLES AND GOUGES:

(1) Repeat Steps 1 & 2.

(2) Mix gelcoat as before in Step 3 except mix an equal amount of milled fibers with this gelcoat, using a

putty knife or small flat stick. Then add two drops of catalyst using an eye dropper for accurate

measurement. For a half dollar size pile of gelcoat, this amount of catalyst will give you 15 to 20 minutes

working time before it begins to gel.`34566790—f   .

(3) Work this mixture of gelcoat, fibres and catalyst into the damaged area. Use the sharp point of a putty

knife blade to press it into the bottom of the hole and to puncture any air bubbles, which may occur. Fill

the scratch or hole about 1/16” above the surrounding undamaged area.

(4) Repeat Steps 5, 6 & 7.

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