Gelcoat Repair - How to Fix Surface Damage on Boats

Gelcoat Repair

Gelcoat repair is inevitable for most boats after extended time at sea. Common reasons include spider cracks, surface erosion, or exposed laminate.
The good news? Most gelcoat repairs are simple DIY tasks that can save you significant costs.

Prepping the Damaged Area for Gelcoat Repair

To ensure a successful gelcoat repair, proper surface preparation is essential.

  1. Remove damaged material by chipping or grinding.
  2. Feather the edges using coarse sandpaper (e.g., 240-grit) to create a bonding surface.
  3. Avoid sanding too deep—do not expose the glass layer.
  4. Clean the area with acetone to remove contaminants.

Gelcoat Application Tips

Tricel Composites offers six standard gelcoat colours:
White, Black, Dove Grey, Dark Olive, Bright Blue, and Clear.
Clear gelcoat can be pigmented to match your boat’s finish.

  • Mix gelcoat with 2% catalyst at room temperature for ~20 minutes working time.
  • Adjust catalyst slightly for cold or warm conditions:
    • Cold: increase slightly (max 3%)
    • Warm: decrease slightly (min 1.5%)

Apply with a brush or matchstick depending on depth.
Remove masking tape before full cure to avoid edge disruption.
Cover with sandpaper to reduce air bubbles and sanding time.

For deeper repairs, sand the first layer before applying a second coat.

Finishing Touches to Gelcoat Repair

Once cured:

  1. Wet sand with 240 to 1000 grit paper.
  2. Blend edges until flush with surrounding surface.
  3. Polish using a motorised buffer and lamb’s wool pad.
  4. Use Farecla compounding paste for a high-gloss finish.

Read More...