Walker Bay Generalion Owner's Manual - Caution
21
For repairs, parts, or service contact your local dealer or Walker Bay® customer service at:
email: info@walkerbay.com
GELCOAT REPAIR:
Gelcoat gets chalked or faded over time if it is not taken care properly. And scratches or cuts could happen.
Here below are some instructions on gelcoat repair.
Surface scratches can be buffed out of gelcoat with polishing compound, but deep scratches must be filled.
When the gelcoat surrounding a scratch is in good condition, the filler of choice is gelcoat paste, which could
be purchased from marine supply stores. Repair kits are comprised of a small amount of gelcoat paste and
hardener, a selection of pigments, mixing sticks, and sealing film. Also, buy a flexible plastic spreader if you
don’t already have one. You will also need sheets of 150-, 220-, 400-, and 600-grit wet-or-dry sandpaper.
If you are repairing several scratches, add a small bottle of styrene to your list of supplies. Wiping each scratch
with styrene just prior to filling it partially reactivates the old gelcoat, resulting in some chemical bonding
between the old gelcoat and the new.
Preparing the Scratch
Never try to repair a scratch by simply painting over it with gelcoat. To get a permanent repair, draw the cor-
ner of a scraper or screwdriver down the scratch to open it into a wide vee. This is the time to wipe the open
scratch with styrene to reactivate the old gelcoat.
Catalyzing
The hardener for gelcoat is the same as for any polyester resin-methyl ethyl ketone peroxide, or MEKP. Gelcoat
resin usually requires 1 to 2 percent of hardener by volume (follow the manufacturer’s instructions). The
mix shouldn’t kick (start to harden) in less than 30 minutes. Hardening in about two hours is probably ideal.
Always err on the side of too little hardener. Also be certain to stir in the hardener thoroughly.
Spreading Gelcoat Paste
Work the gelcoat paste into the scratch with a flexible plastic spreader. Let the putty bulge a little behind the
spreader; polyester resin shrinks slightly as it cures, and you’re going to sand the patch anyway. Scrape up
any excess paste beyond the patch area.
Covering the Repair
Gelcoat will not fully cure in air. To seal the surface of a scratch repair, cover it with a sheet of plastic film. The
kit may include sealing film. Otherwise a section of kitchen “zipper” bag works especially well because it tends
to remain smooth and the gelcoat will not adhere to it. Tape one edge of the plastic to the surface just beyond
the repair, then smooth the plastic onto the gelcoat and tape down the remaining sides.
Sanding and Polishing
After 24 hours, peel away the plastic. A 5 1/2-inch length of 1 x 2 makes a convenient sanding block for a
scratch repair. Wrap the block with a quarter sheet of 150-grit paper, and use the edge of the block to confine
your sanding to the new gelcoat. Use short strokes, taking care that the paper is sanding only the patch and
not the surrounding surface. Never do this initial sanding without a block backing the paper.
When the new gelcoat is flush, put 220-grit wet-or-dry paper on your block and wet sand the repair, this time
with your block flat. Use a circular motion and keep a trickle of water running on the sanding area. Feather the
repair into the old gelcoat until your fingertips cannot detect a ridge.
Abandon the block and switch to 400-grit wet-or-dry paper. Wet sand the surface until the repair area has a
uniform appearance. Follow this with 600-grit wet-or dry.
Dry the area and use rubbing compound to give the gelcoat a high gloss. Buff it with a circular motion, using
heavy pressure initially, then progressively reduce the pressure until the surface becomes glassy. If the gelcoat
shows swirl marks, buff them out with a very fine finishing compound.
Finish the job by giving the repair area a fresh coat of wax. If your color match is reasonably good, the repair
will be virtually undetectable.
REPAIRS
CAUTION
In the event of more serious hull damage such as a hole or crack do not use the boat. Contact Walker
Bay® customer service for repair information.