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Author Topic:   Gelcoat Repair
paddyt111 posted 05-26-2008 11:33 AM ET (US)   Profile for paddyt111   Send Email to paddyt111  
I finally had a change to wash, wax and baby my new 2005 Boston Whaler yesterday. Nothing like cleaning a boat to get intimately acquainted with all the nooks and crannies. I found the power washer of great help for getting rid of the dirt on the textured floor. It did a better job than my brush. I made a classic mistake while getting the pressure right and chipped the gel coat with the spray nozzle in one area. There is a 0.33-inch dark mark in the bow deck where I chipped it. Should I seal this? If so, what do you recommend I use? I don't want the chip to increase in size, although it doesn't appear that it will. Pat
jimh posted 05-26-2008 02:58 PM ET (US)     Profile for jimh  Send Email to jimh     
I can't imagine that the spray of a power washer would be able to create a chip in the gel coat layer if everything about the laminate were normal. I suspect the spray may have hit an area of the gel coat that was already cracked or damaged, and the pressure of the water forced it off.

Repair of gel coat is described in an article in the REFERENCE section:

Jordi posted 05-28-2008 07:44 AM ET (US)     Profile for Jordi    
A power washer with the wrong nozzle and pressure can "chip" off the gel coat in the wrong hands. Get Spectrum Gel Coat repair kit ($20) and have the gel coat specialist create the diamond cut pattern of the deck. Your boat is probably Whaler White Flex (confirm) per Spectrum.
gbcbu posted 05-28-2008 09:49 AM ET (US)     Profile for gbcbu  Send Email to gbcbu     
I just saw an episode of "Shape Shape TV" a day or so ago and they had a piece on just this type of repair. It included a pattern for non-skid. I think it was an interlux product but if you can find the website for ship shape TV it should be there. Uncanny just how similar your need is to the repair they did on the show...Good Luck.
gbcbu posted 05-28-2008 09:52 AM ET (US)     Profile for gbcbu  Send Email to gbcbu     
here's the link:

I believe it is the show #1312 "Painting the Pursuit"

Chuck Tribolet posted 05-28-2008 08:54 PM ET (US)     Profile for Chuck Tribolet  Send Email to Chuck Tribolet     
Don't go with "one size fits none" pattern solutions. There's
lots of technology to pull a pattern off YOUR deck.


320OR posted 06-05-2008 01:27 PM ET (US)     Profile for 320OR  Send Email to 320OR     
I am assuming this chip is on the non-skid surface of your deck. You must route out the area with a dremmel type tool leaving a nicely roughed surface for your gel-coat to bond.. Then clean the surface with some acetone and a rag and let dry. You can then catalyze a small amount of gel-coat in a cup. You will then touch-up the area in the non-skid with the gel-coat leaving the touch-up slightly higher than the non-skid surface. You will then let the gel coat dry for about an hour if you followed the catalyzation steps properly. While it is curing, See if you can find a hacksaw or jigsaw blade that fits perfectly between the diamonds. You dont want a blade that is too wide because it will cut a wider channel between the diamonds, However you dont want one too narrow because the channel will be too narrow and you will have too repair it with a wider blade. If you have a hacksaw blade you will have to cut it down too about 3 1/2 inches. If the blade is too wide you can sand on it with some 100 grit sand paper too narrow it. Once you find a blade you can test it by sliding it between an area of nonskid that is not damaged. If it slides smooth you are ready to cut in your bag pattern. First you must knock down your touch-up wih a little piece of 100 grit, the touch-up must be level with the surrounding diamonds, However, you do not want to sand too much because the area surrounding the touch-up, the diamonds will slowly dissappear., so try to focus your sanding on the touch up itself. After sanding, blow off excess dust and line up your new non-skid blade in a channel leading too the touch-up. You usually want to start at the buttom of the touch-up closest too you. You also want the teeth of the blade facing in the opposie direction of your cut stroke. You can slowly slide the blade through the channel and into the touchup Go slowly at first because you want to keep a strait line until you hit the channel on the other side of the touch-up. You will then, as long as you have a strait line connecting from one channel to he next acrossed the touchup you wil slowly cut back and forth with the blade, creating a whole new channel. You will stop when the channel is completely flush all the way across. When you are satisfied with your line, slide the blade too the next channel and repeat the process. When your strait lines are complete, you will have too do the diagonal lines. Before this step, you should have a flattened touch-up with lines through it Now you must find the channels that run diagonal that form the diamonds. You will repeat the cutting process going back and forth with the blade and slowly your diamonds will appear. You must be careful not to let the blade slide off the channel because it will ruin the line And it will saw off parts of the diamonds. If you do it right, this is the most effective , cheapest wat to repair small defects in non-skid.
falcon posted 06-10-2008 10:33 AM ET (US)     Profile for falcon  Send Email to falcon     
You can also copy the non skid with silicon.Use release wax on an area away from the repair, pour the liqid silicon or rubber on the gel,let dry.Then as the gel on the repair starts to catilize place the copied non skid on the repair and add a weightto push the pattern onto the repair.Try this method on a piece of wood to get the weighting right for the size of your repair.If the area is very large a company Gibco in Texas makes patterns for repair.
gbcbu posted 06-10-2008 01:27 PM ET (US)     Profile for gbcbu  Send Email to gbcbu     
there are small square reverse patterns for applying over the gelcoat while drying that will match your non-skid surface.

Which repair method did you use?

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