posted 08-12-2002 10:01 AM ET (US)
I recently epoxied and gel-coated (with the spectrum patch kit)over 30 misc screw/bolt holes in my '84 Montauk, and have the following observations:1. A littel past goes a long way. If you mix the patch kit in two equal batches, you will waste a lot of material. I recommend scooping out the paste with a measuring spoon (teaspoon maybe). See how many spponfuls you have, then do some math to see how many drops of hardner per spoonful. Do this before you mix any paste at all so you can get the proportions correct.
2. After mixing, spread the paste around in the container. A larger mass of material sets up quite quickly, and I ended up wasting a lot of material because it set up in the mixing container. Where I had the material spread out in a thin layer, the working time was much greater.
3. The color of the paste was a litte darker than the hull, even after wet sanding, compounding, polishing, and waxing the hull. Still looks pretty good. To do it again, I would mix in a touch of white pigment.
4. Build up the area to be patched with epoxy or an initial coat of patch paste first so that you are not trying to fill a deep area in one coat.
5. Taper the existing surrounding gel coat. For screw holes I found that using a much larger drill bit in the hole gives a nice bevel to the existing gel coat, and makes blending in easier.
6. Over fill and then sand down, or plan on putting another coat of patch on. I found that after sanding, I had not filled in with the patch paste enough, thus leaving holes and pits to fill in with another round of paste.
7. Sand the patch as early as you can. I found that wet sanding by hand with 240 grit took the patch down fairly well (that Sh*t is hard!), and then wet sand with 400, 600, 1000, etc to your own satisfaction to blend in. I had limited luck with a sanding block, and found that a piece of sand paper and my fingers was the best way to take off the paste quickly.
Good luck!