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A Simple Gel Coat Repair Method
By Douglas Malat..

Boat repairs are anything but cheap when done professionally. Repairing your boat's gel coat is simple enough to do and you can save hundreds of dollars in the process.
How to fix a crack:
Did your jib pole come loose? Did the anchor swing too wildly or did your landlubber friend forget to tell you he had on his golf shoes? Don't laughit happens. I used to get all upset when I saw the slightest damage to my gel coat and thought it would never be the same. You will always see it even after a mint fix. But no one else will, even if the fix is not perfect. Power boats get cracks here and there from the pounding as they cut through waves. Sailboats get it the same way, plus all the heeling over they do.
I have read all the books and articles and found they all do a great repair. Some more complicated than others. I took the best from each and now do this procedure for a great fix.
What you will need:
1. Get a Bondo can (auto/marine body filler), that is short and wide, with a plastic top. This comes with the catalyst you will need.
2. Sandpaper/wet & dry (emery cloth), 1 sheet of each: #220, #320, #400, #600
3. Manufacturer's Gel Coat color (if you can't get a hold of it, you can use tints available at Home Depot to match your boat color.
4. Acetone
5. Masking Tape
6. Spray bottle, sold in marine supply or hardware stores.
7. Screwdriver or metal pick
8. Newspaper
As you can see, there is a very minimal investment in purchasing the necessary materials, plus they should last through about 10 repairs.
1. In order to repair a crack, clear the area. Take a good look at it and then take some acetone on a rag and clean in and around the crack. A little goes a long way. Too much is no good. This cleans the wax, dirt, and stains off so you now can see clearly how far the crack really goes and what color you should mix, too. The factory gel coat that was sent is the original color of the boat's gel coat. By sanding lightly with 300 grit wet you will bring this color out, but it will not match the rest of the boat. You may have to add a touch of yellow or gray/black to get that faded color. Look from the sun. If you plan to compound to the original color, then go with the factory color, otherwise, tint it down.
2. Now that the gel coat is ready, let's get back to the crack. After using some acetone and sanding right around and in the crack, use a flat hand screwdriver or metal pick to loosen any material in the crack. Make good, fat edges at either side of the crack. Chip away at it until you get to good, uncracked gel coat. Sand the area, blow out and acetone again.
3. Tape newspaper around the repair area with masking tape to prevent any overspray from going on the rest of the gel coat surface.
4. If the crack is deep, fill it in with white bondo. I like the kind with fiberglass strands. Mix the bondo with the catalyst, and then apply it to the crack using the flat edge of the screwdriver. Don't let the mixture go outside the crack. Try to keep the filler level with the rest of the gel coat area. Allow the repair to dry. Weather and the balance of bondo to catalyst will effect the drying time. When completely dry, give the repair a sanding with the 220 or 300 grit sandpaper and make a slight depression in the plastic. Now, clean the area again with the acetone.
5. Place the gel coat into the jar part of the sprayer. Add some acetone to thin it out. Add a bit of catalyst. Cover the jar, shake it and you're set to spray the repair area.
6. Before you start spraying the repair area, practice first on cardboard. Get yourself used to the left and right motion of spraying. This creates an even coat. Begin from the left, squeeze the nozzle, move to the right, release the nozzle. Repeat this process, beginning from the right. Once you get the feel, spray the repair area. Don't try to get full coverage in just one or two coats. Several thin coats will come out much better. Warm weather makes for quick drying time. If it's cool out, point a utility lamp at the repair area. Drying should take between 15 minutes to an hour. If you're not in a rush, just let it dry overnight. If the proportion of bondo to catalyst is off balance, you may find the area won't dry. When this happens, just remove the bondo with acetone and give the repair another try. It takes a bit of practice to get the amount of catalyst right, but you'll be a pro before long.
7. After the gel coat hardens, take that plastic cup top and put some water in it. Rip a 1" x 4" piece of emery cloth off the 220 or 300 grit. Soak it a bit and also put some water over the repairs. Wipe it around. Now, with the emery cloth pliable, lightly sand over the repair. Feel the coarseness of the area you are sanding. Add more water if it feels pretty flush with the surrounding area. Move to 400 grit, then to 600 grit. Get it nice and wet. Watch not to take too much gel coat off. Do a little check.
8. The last step is applying the compound. Apply a modest amount, blend in using water. Finish by washing and waxing the area. It won't be a perfect match, but it will blend in over time. If you have a scrape to repair, which is simply a larger damaged area, sometime just a sanding is enough to fix the problem. Try using ith wet 300 or

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400 grit emery cloth. That may be all that is required.
With a little practice, the gel coat repair is like riding a bicycle. The savings makes it worth the time.
Douglas Malat is a licensed captain, freelance writer and co-author of YachtAuthority.com, where you will find fiberglass gel coat repair services in your area. Click here for article submission.

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