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How Much Does Gel Coat Repair Cost?

gel coat repair cost

Scratches and gouges in gel coat can be a real nuisance. They expose the fiberglass matting underneath and can lead to gel coat blistering down the line. The best solution is to get a professional to fix them. This can cost a lot but will give you a near-perfect repair.

Cost of materials

The cost of materials used in gel coat repair can be very expensive. These can include a fiberglass filler, gel coat reducer, disposable spray gun, sandpaper, and wax. The price of these products can vary depending on the brand and size of the job. You can find most of these items at your local boat store or online. Using the right materials is essential to ensure a quality finish.

The first step in any gelcoat repair is to clean the surface and prepare it for coating. You should use a brush to apply the first coat of gelcoat and let it dry. Once it is dry, sand the area smooth and then apply another coat. Repeat the process until the surface is even and free of blemishes. It is important to protect yourself from the chemicals and dust involved in gelcoat repair. Using a respirator and disposable gloves is recommended. Be sure to follow all safety instructions for the products you are using.

Re-gelcoating your boat is a great way to restore its appearance and prevent damage. It can also provide a more durable finish than traditional paint. But before you re-gelcoat your boat, you must consider the cost of materials and labor. This will determine how much the project will cost. Generally, you can expect to pay around $8000 for a 16-foot boat.

It is important to note that if your gelcoat has major cracking and crazing, you will need to do considerable work to repair it. This will require sanding and grinding to make it smooth and even, followed by epoxy laminates and fillers for patching. This is not a project for the average boat owner, and you should hire a professional.

Performing invisible repairs to the gelcoat on your own is not difficult if you take it slowly and carefully. You can start by repairing a small section of the cabin top, or you could try making a gelcoat repair to a vertical surface such as a hull or flybridge. The latter type of repair is more challenging, but it can be done with the same basic techniques.

Cost of labor

Whether the result of chafing by rope or contact with docks, trailers, rocks, or other boats, gelcoat is prone to chips and scratches. These blemishes are not only cosmetic problems, but they can weaken the laminate beneath. Fortunately, they are fairly easy to repair. The key is to use a methodical approach and to avoid making the problem worse.

Most gelcoat scratches and chips are the result of impact damage, such as from a dropped winch handle or cleat. These are relatively common, but if left unattended, they can cause serious structural problems. They also reduce the boat’s resale value. Fortunately, these chips can be easily repaired by grinding away the damaged gelcoat and applying new gel coat. A good finish will make the repairs nearly invisible.

Before attempting a gelcoat repair, you should always wet-sand the area to smooth it and remove any ridges. Using a sanding block and 400-grit wet-sanding paper will help you get the best results. You can also try 600-grit sandpaper to prevent ridges and create a smooth surface for the filler. Then, wipe the sanded area with a damp cloth to make sure it’s ready for the next step.

When you’re done sanding, clean the area and apply some acetone to the surface of the gelcoat. This will help remove any remaining wax and will help the filler bond better to the fiberglass. Then, wet-sand the repair area again, this time with 600-grit paper. This will prepare the area for the final step of blending the repair into the surrounding gelcoat.

For deep gouges, you can also use a Dremel tool with a burr bit. The burr will help you cut off any sharp edges in the gelcoat. You can then apply a small amount of wet-sanding filler with a plastic spatula. Make sure the filler is not too thick, and then sand again to smooth it.

If the damage is severe, you may need to re-gelcoat the entire vessel. This is more costly than painting, but it will provide a much better finish and will add thickness and toughness to your vessel.

Cost of time

From rope chafing on cockpit coamings to impact damage from dropped winch handles, gelcoat scratches and gouges are a reality for most boats with miles under their keels. Luckily, the process to repair them is not as hard as you might think. It requires preparation and a methodical approach but, if done right, the result is a surface that looks new again and helps support the structure of the laminate underneath.

First, clean the area to be repaired using acetone. This removes any dirt or debris that could affect the bonding of the new gel coat. Next, apply a small amount of gelcoat paste to the damaged area using a putty knife. Then, smooth the paste with a plastic spreader. Once you have smoothed the paste, cover it with a piece of clear Mylar film (available at office supply stores). This protects the gel coat and keeps it from getting dirty before it cures.

When the gelcoat has cured, wet-sand the area to create a smooth surface. Make sure you wear a mask and eye protection when sanding, especially when using a power drill with a burr bit. You may also want to consider a Dremel tool, which is a rotary tool with bits of different shapes that can be used for sanding and grinding.

If the area is large, apply a layer of clear Mylar to protect it from further water penetration. If the crack is very deep, you will need to grind it deeper and wider before applying the gelcoat. If the crack is below the waterline, it should be checked by a professional.

Once the gelcoat has cured, sand it with 80-grit sandpaper to smooth the surface and prepare it for painting. Immediately clean up the taped-off area with acetone to prevent sanding dust from affecting surrounding areas. Apply a few layers of gelcoat, leaving 15-20 minutes between each application. After the gelcoat has cured, buff it with rubbing compound and wax. This restores the shine and gives the finish a nice luster. To ensure that you get the best results, it is important to follow the manufacturer’s instructions for mixing gelcoat and catalyst. It is better to mix a little more than you need and work quickly, as the gelcoat can dry very fast.

Cost of equipment

No matter how careful you are on your ship, nicks and scratches in gel coat are a fact of life. Botched landings, fishing gear, and the occasional tool that slips from your fingers can all leave unsightly marks in your fiberglass. But the good news is that repairing gel coat gouges and scratches is easier than you think.

A good gelcoat repair kit contains all the materials you’ll need for the job. Most of the components can be found in hardware stores or purchased at plastic materials dealers. You’ll also need a few tools, including a heat gun, sanding block, and rotary tool. In addition to these items, you’ll need a small amount of polyester resin and epoxy-based filler. The epoxy-based filler is more expensive than the polyester, but it offers better adhesion and will last longer.

The first step in a gelcoat repair is to choose a section of the hull that is identical in color to the damaged area. This will serve as the mixing palette from which the gelcoat will be colored-matched. Once the gelcoat has been mixed to the correct ratio, enough plain white pigment should be decanted to complete the repair.

Next, the sanding process begins. A 400-grit sanding block is used to smooth out the gelcoat, paying special attention to the edges around the strap. The sanding process is done in short bursts, and the surface should be cleaned with acetone after each pass. Once the sanding is completed, it’s time to apply the new topcoat.

Gelcoat is similar to paint in that it needs to be applied in a thin layer. If you apply too much at once, the gelcoat will run and sag, making it difficult to get a consistent and even finish. To avoid this, apply several thinner layers and wait for each to cure.


If you’re repairing deep gouges, it’s important to use an epoxy-based filler instead of a polyester-based one. Epoxy is more durable and adheres better to the fiberglass core. Also, make sure that the deep gouges are shaped in a V shape. Otherwise, the gelcoat might bridge either side of the crack and leave a gap underneath.