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Author Topic:   Gel Coat Cracks

ONO posted 04-03-2003 11:59 PM ET (US)
My 1997 Whaler has gelcoat cracks on the nonskid and into into the smooth areas immediate adjacent to the non skid (1-2 inches)
I have Dremeled into smooth areas and have found the fibreglass underneath to be dry and sound. The biggest area to repair has 1-2 cracks per inch for 12 inches. When cleaned out the cracks are 1/8-1/4 inch wide.
I am looking for advice on how to repair the gelcoat cracks to improve the boat's integrity while maintaining the cosmetics.
My first thought was to only only fix the big cracks on the boats smooth area and stop at the nonskid. I feel that the repairs in the nonskid would be uglier than the hairline cracks
My first question is how to repair.
Do I use West System Epoxy with filler then cover with Whaler matched gelcoat. Or is there a better way.
Since the deep cracks are only on the smooth areas is there a downside in only fixing them and leaving the hairline cracks in the non-skid?
Is there a way to fix the hairline cracks in the non skid and replace the pattern?
Any thoughts on how these cracks occured, The previous owner said that it was due to the boat being left uncovered in the Sun with a dark carpet over the non skid, Does this make sense

Thanks for the help

ONO posted 04-04-2003 08:12 AM ET (US)
I looked through all the past posts and was able to find enough info to start a cosmetic repair job.
The only thing I am still curious about is what could possible be the cause for so many cracks in a relatively new boat and is there any thing else I should be looking at to ensure that this is not the tip of an iceberg
PFSQUAN posted 04-04-2003 08:48 AM ET (US)
Gelcoat is not structural and has little strength compared to fiberglass material that is reinforced with resin. Cracks can occur when the gelcoat is applied too thickly or too thinly. Gelcoat does not like sharp bends or angles, again because it offers no structural strength. It is quite possible to crack gelcoat by dropping tools or other heavy items on it. I would think if anything the carpeting would protect the gelcoat from sunlight. Gelcoat doesn't like that either.
hooter posted 04-04-2003 09:28 AM ET (US)
Raise hell directly with BW. You may be able to get them to honor the ten-year hull guaranty, but be ready t'bust a gut in the process. Gelcoat blems and cracks like you describe in a five or six year old hull the price of a Whaler, that's unpardonable.
Bigshot posted 04-04-2003 09:41 AM ET (US)
I agree with Hooter but being you already started gringing you may be SOL. That boat has seen some heavy use to be crazing at that age. My 89 and my 84 are but they are older. Sunlight don't help gel-coat but I do not believe it causes crazing like that, flex does.
ONO posted 04-04-2003 12:58 PM ET (US)
Thanks for the words of encouragement. I am somewhat of a closet boat worker so I do not terrible mind repairing the cracks on the smooth surfaces because I believe that I can get it looking new again. It is comforting to know that the gelcoat is strictly cosemetics.
However it is a different story with the non skid. I believe that I will contact whaler and post notice of the problem.
Overall If the problem stays where is it I can live with it, If the problem does return I will be ready "t'bust a gut"
PS The boat has low engine hours <25 and was kept on a drydock and/or a trailer. If the damage was caused by flexing it must have filled up with rain water. However I can see no damage to the bottom
ONO posted 04-04-2003 02:56 PM ET (US)
WOW !!!! I just finished Dremelling all the cracks in the Gelcoat and there were over 400. Most of them were in the interior corners... where the deck transistion into the sides. The worst areas are where the gelcoat is thickest.
Boy do I feel like an idiot, When I bought the boat I focused on the engine, the transom and the bottom. They all checked out.
I guess I was naive, I trusted the Whaler name, the dealer ( I have been a customer for 14 years). Oh well
I took some photos if any one is interested
send me a note @m.acosta@cox.com
alkar posted 04-06-2003 11:42 AM ET (US)
ONO, you don't live in Pensacola do you?
ONO posted 04-09-2003 12:03 AM ET (US)
Nope, I am on the west coast,
Taylor posted 04-09-2003 04:01 PM ET (US)
Hey ONO, I tried that email address (m.acosta@cox.com) and got a bounce. I'd be interested in seeing your pictures. My email's in my profile. I'll bet a lot of people might be interested, so do a good job at the photodocumentation.
ONO posted 04-16-2003 02:16 PM ET (US)
Sorry guys, I goofed my home email account is m.acosta@cox.net not cox.com, Sorry

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Author	Topic: Gel Coat Cracks
ONO	posted 04-03-2003 11:59 PM ET (US) My 1997 Whaler has gelcoat cracks on the nonskid and into into the smooth areas immediate adjacent to the non skid (1-2 inches) I have Dremeled into smooth areas and have found the fibreglass underneath to be dry and sound. The biggest area to repair has 1-2 cracks per inch for 12 inches. When cleaned out the cracks are 1/8-1/4 inch wide. I am looking for advice on how to repair the gelcoat cracks to improve the boat's integrity while maintaining the cosmetics. My first thought was to only only fix the big cracks on the boats smooth area and stop at the nonskid. I feel that the repairs in the nonskid would be uglier than the hairline cracks My first question is how to repair. Do I use West System Epoxy with filler then cover with Whaler matched gelcoat. Or is there a better way. Since the deep cracks are only on the smooth areas is there a downside in only fixing them and leaving the hairline cracks in the non-skid? Is there a way to fix the hairline cracks in the non skid and replace the pattern? Any thoughts on how these cracks occured, The previous owner said that it was due to the boat being left uncovered in the Sun with a dark carpet over the non skid, Does this make sense Thanks for the help
ONO	posted 04-04-2003 08:12 AM ET (US) I looked through all the past posts and was able to find enough info to start a cosmetic repair job. The only thing I am still curious about is what could possible be the cause for so many cracks in a relatively new boat and is there any thing else I should be looking at to ensure that this is not the tip of an iceberg
PFSQUAN	posted 04-04-2003 08:48 AM ET (US) Gelcoat is not structural and has little strength compared to fiberglass material that is reinforced with resin. Cracks can occur when the gelcoat is applied too thickly or too thinly. Gelcoat does not like sharp bends or angles, again because it offers no structural strength. It is quite possible to crack gelcoat by dropping tools or other heavy items on it. I would think if anything the carpeting would protect the gelcoat from sunlight. Gelcoat doesn't like that either.
hooter	posted 04-04-2003 09:28 AM ET (US) Raise hell directly with BW. You may be able to get them to honor the ten-year hull guaranty, but be ready t'bust a gut in the process. Gelcoat blems and cracks like you describe in a five or six year old hull the price of a Whaler, that's unpardonable.
Bigshot	posted 04-04-2003 09:41 AM ET (US) I agree with Hooter but being you already started gringing you may be SOL. That boat has seen some heavy use to be crazing at that age. My 89 and my 84 are but they are older. Sunlight don't help gel-coat but I do not believe it causes crazing like that, flex does.
ONO	posted 04-04-2003 12:58 PM ET (US) Thanks for the words of encouragement. I am somewhat of a closet boat worker so I do not terrible mind repairing the cracks on the smooth surfaces because I believe that I can get it looking new again. It is comforting to know that the gelcoat is strictly cosemetics. However it is a different story with the non skid. I believe that I will contact whaler and post notice of the problem. Overall If the problem stays where is it I can live with it, If the problem does return I will be ready "t'bust a gut" PS The boat has low engine hours <25 and was kept on a drydock and/or a trailer. If the damage was caused by flexing it must have filled up with rain water. However I can see no damage to the bottom
ONO	posted 04-04-2003 02:56 PM ET (US) WOW !!!! I just finished Dremelling all the cracks in the Gelcoat and there were over 400. Most of them were in the interior corners... where the deck transistion into the sides. The worst areas are where the gelcoat is thickest. Boy do I feel like an idiot, When I bought the boat I focused on the engine, the transom and the bottom. They all checked out. I guess I was naive, I trusted the Whaler name, the dealer ( I have been a customer for 14 years). Oh well I took some photos if any one is interested send me a note @m.acosta@cox.com
alkar	posted 04-06-2003 11:42 AM ET (US) ONO, you don't live in Pensacola do you?
ONO	posted 04-09-2003 12:03 AM ET (US) Nope, I am on the west coast,
Taylor	posted 04-09-2003 04:01 PM ET (US) Hey ONO, I tried that email address (m.acosta@cox.com) and got a bounce. I'd be interested in seeing your pictures. My email's in my profile. I'll bet a lot of people might be interested, so do a good job at the photodocumentation.
ONO	posted 04-16-2003 02:16 PM ET (US) Sorry guys, I goofed my home email account is m.acosta@cox.net not cox.com, Sorry