Method for Casting Non-skid Pattern into Deck Repair
Posted: Mon May 25, 2026 7:06 pm
BACKGROUND
I recently repaired a hole on the deck of by Boston Whaler boat, and I want to share my method. Some fuel burned a hole in the gelcoat on the deck, and wanted to make a repair with the same non-skid pattern. Most repair kits don't offer a proper Boston Whaler non-skid pattern, so I made my own.
PROCESS
ILLUSTRATIONS:
I recently repaired a hole on the deck of by Boston Whaler boat, and I want to share my method. Some fuel burned a hole in the gelcoat on the deck, and wanted to make a repair with the same non-skid pattern. Most repair kits don't offer a proper Boston Whaler non-skid pattern, so I made my own.
PROCESS
- cleaned out all the loose gelcoat bits;
- made a mold from the good area of the deck. I purchased (green) silicone mold-making material from Amazon;
- used "whaler tab" gelcoat and filled the holes in the deck with the gelcoat using a popsicle stick, with just a little dab to fill the holes. At this stage the gelcoat is smooth surface;
- placed the green mold over the repair in order to press a relief into the smooth wet gelcoat;
- let the gel coat cure for 24 hours and then peeled off the silicon mold.
ILLUSTRATIONS:
- Fig. 1. The mold (green) made by a silicon casting from a non-damaged section of the deck non-skid pattern.
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- Fig. 2. Overhead view showing resin being added to repair area.
- F2a.jpg (52.74 KiB) Viewed 305 times
- Fig. 3. Extreme close-up view of deck showing non-skid pattern [and what appears to be repaired areas].
- F1a.jpg (103.97 KiB) Viewed 306 times