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  1. How to make a Fibreglass Mould

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  2. Gelcoat Repair

    Gelcoat repair is inevitable for the vast majority of boats after a sustained period of time on the sea. Common gelcoat repairs are often applied for spider web cracks or eroded gelcoat to the point where the base laminate is starting to show.

    The good news is, the vast majority of gelcoat repairs are easy to undertake and will save you lots of money by repairing them yourself.

    Prepping the damaged area for repair

    To ensure a successful repair the area must be prepped accordingly.

    The first step is to chip or grind down any damaged material and finish feathering the edges with a course sandpaper such as 240-grit. This will give the new layer of gelcoat a suitable are to bond with. Care should be taken to not sand down too far and reach the glass.

    Once the area has been sanded down, it should be wiped with Acetone to remove any contamination.

    Abrasive Sand Paper

    Gelcoat application

    FibreGlassDirect supply 6 standard gelcoat colours; White, Black, Dove Grey, Dark Olive, Bright Blue and Clear. The clear gelcoat may also be pigmented if required. One or more mixes of pigment may be required to achieve an exact match to the rest of the boat.

    Gelcoat must be mixed with

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  3. Boat Repair

    Fibreglass has been used in the Boat Repair industry for many years thanks to its durable and versatile properties. It is used primarily as it is so light weight and strong. During the course of its lifetime, all fibreglass boats will undergo maintenance to keep the boat looking its best and to ensure maximum protection. Common boat repairs undertaken by the customers of FibreGlassDirect are in relation to small cracks, gelcoat discolouration and patching small holes.

    For the purposes of this boat repair article we will focus on patching a small hole in a fibreglass boat.

    What materials do you need?

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  4. Gelcoat Application for Open Moulding

    Conventional Gelcoat application for open moulding

    Source: CCP Cook Composites and Polymers Co, 2009 Composites Applications Guide, Eleventh Edition.


    Proper application of gelcoat is critical to producing cosmetically appealing and durable parts. Improperly applied gelcoat increases the cost of the part. The amount of additional cost incurred depends on the number of rejected parts as well as the effort required to rework the parts. Making the investment of properly applying the gelcoat can pay big dividends by reducing rework and scrap. Proper gelcoat application includes material preparation, equipment calibration, use of trained spray operators and appropriate spray methods.


    A conventional gelcoat is applied with spray equipment. Brushing of gelcoats is not recommended. The following information assumes that the proper gelcoat spray equipment has been selected and that equipment is being properly maintained.

    The ideal catalyst level for most gelcoats is 1.8 percent at 77ºF (25ºC). However, the catalyst level can be varied between 1.2 percent and 3 percent to compensate for specific shop conditions. 

    Catalyst levels below 1.2 percent or above 3 percent should not be used as the cure of the gel coat can be hindered permanently. Refer to product data sheets for specific catalyst recommendations. There are a number of catalysts available for both resins and gelcoats. It is imperative that the proper catalyst be selected. Only MEKP-based catalysts should be used in gelcoats. Broadly speaking, there are three active components in an MEKP-based catalyst. They are hydrogen peroxide, MEKP monomer, and MEKP dimer. Each of these components play a role in the curing of unsaturated polyesters. Hydrogen peroxide initiates the gellation phase, but

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