I was looking at my quiltwork of a stern cap a couple of months ago and wondering why I was bothering to put it back together instead of molding a new one with gelcoat already on. I had just decided to make a mold and do it when you did this one - now I am sure it is the right idea. It is going to be lighter and stronger as a newly molded piece. I guess the old one is now just a proof of concept and cover to keep leaves out til the new one gets made.

I will be using a Vinyl Ester gelcoat that is very close in color to the old one for the new decks and stern cap. If the color match is not good enough I will go over it with paint. The reason I'm using gelcoat is that it is thicker than paint alone; when the surface gets worn or damaged it won't show as bad if wear/damage does not go all the way through the 0.040" to resin/glass. I'm using VE gelcoat since it is supposed to be stronger, harder, and more flexible than poly gelcoat. I will find out but I already know it is harder to get :rolleyes:.

Like Don says, Moose's interior looks good and is perfect for what he does.

Gelcoat first is the way to go. Unless you vacuum bag you will have some pinholes in your layup. Gelcoat buries them. It also gives you something to sand if there are any imperfections.

Reading moose’s build now.

Rolling gelcoat on the gunnels and interior is a great option if you plan on not worrying about chips and dings. I use my boat with no regard to scuffs, scrapes and dings and it really makes using the boat much easier as you can always fix anything that happens which will always occur.

One thing I will recommend is that you choose a standard color for these areas from a reliable dealer. This will make touch up much easier. Also I would recommend using Duratec additive instead of wax or surfacing agent. Duratec adds uv protection and gives you a durable, glossy finish that cleans up well. The only issue is that you will need to apply multiple coats to get the thickness you need on the high traffic areas on the gunnels and transom cap. I also keep a small container of touch up mixed in the refrigerator. When I have a chip I just mix a drop or two of premixed duratec and gelcoat with a drop of hardener and dab it in with a small brush.

Thanks Moose I’m not one to flip out if I get a scratch. If the boat isn’t getting beat up we are not using it hard enough. I do want it to look reasonably good and be easy to clean. I like your comment of selecting a standard color the make it easy to repair. Between spearguns tanks and coolers I will be busy.

Did you mix duratech with each coat or just the top layer? Also did you did any sanding and buffing?

Rolling Gelcoat
 

Thx Moose. Being in the midst of a transom pour and redo, your suggestion intrigued me for the transom cap. Do you have some other suggestions like type of roller for the gelcoat, required preparation, etc. I presume you are doing a little scuffing up between the multiple coats of gelcoat to get the desired thickness. Thx.

Sorry for the delay.... Yes I go 1/3 duratech to gelcoat. You can add coats within the hour or if still slightly tacky. If it goes past that I score it with a 3M green pad and add more coats.

I have had varied success with foam rollers that gave me the best finish but they are one time use and the mix cannot get tacky or the foam roller comes apart. The Duratech really helps with getting the gelcoat to "lay down" nice as long as you don't let it start to set. I only do that if I want a little texture, which I do on the top of the gunwales and transom cap. I would also recommend the final few coat be 50/50 Duratec. The mix will be a little loose but the added Duratec will yield its best UV protection at that mix rate.

I think If I had to do it again I may have gone just straight gelcoat for the build up and then duratec on the top coats but I wanted to have a somewhat consistent hardness and uv resistance.

Gelcoat Rolling
 

Moose- thanks. Think I’ll try some trials before the real transom cap.

Good idea, I think you will find you need to apply double of what you think is good. Transom caps and gunnels are high wear areas and it needs to be thick. Also, don’t cheap out on gelcoat. Make sure you are buying builders grade, not “boatyard” buckets that have been sitting for a year. Be prepared for double the price. I made the mistake once and ended up fighting mold on cheap, porous gelcoat. There is also differences in mekp grades. Whoever is selling you the gelcoat will know what you need. Mekp has a short shelf life more so than the gelcoat. Containers need to be well sealed and not stored in a hot nor freezing shed.

When I get ready to apply, I let all my materials get to ambient temp. This especially comes into play if it’s humid. Water is your enemy and if you mix cooler gelcoat than ambient moisture will condense on and in the mix. I’ve learned the hard way on all of the above.

Rolling Gelcoat
 

Moose- Thx again for the additional tips. As I occasionally do, I printed the comments from you and others, to avoid searching for them later.

I am looking for help with the final faring and finish. I just don’t have the time to do it all myself. I’d like to call in a pro where this step is one of the most important. I did a lot of research myself and didn’t find much info out there on gelcoating. I also tried spraying and rolling my under deck hatches with crappy results. I will get a better finished result if I sub it out. I’m still looking for a professional.

If I absolutely can’t find someone to help, I will tackle it myself. This is the best info I found on re-gelcoating. I have a dump gun that would help.
http://www.bertram31.com/proj/tips/re-gelcoating.htm

Getting Gelcoat to new boat standards can be done but has to be done by a pro and there are few and far between people that can do it right. Most all exterior finishes on restorations are sprayed with Awlgrip or other products, not gelcoat and for good reason.

Fairing and surface prep is a whole nother ugly task that needs to be done by the person doing the finish coating. I let a pro do my outside and my wife and I did the interior and cap as I knew what the finish would look like and I was good with that.

Thanks Moose. Not looking for perfection on the gelcoat just for someone to do a better job than I would in less time.

I got a lot done with the cooler weather. I sanded off all the epoxy primer from the floor in preparation for gelcoat. I should have used gelcoat when I laid up the floor in the first place. I tabbed the floor in with a nice radius. The inner transom wall was also tabbed in.

I prepped the center console for final install. It was made with a thin wall and had to be cored. I also gelcoated the inside. The bottom flange was trimmed and prepped to get glassed in.

I fighting to find time to work on it.

I took her by Pirate Marine at port Canaveral and Kustom Karma in Palm Bay for quotes on finishing the fairing, painting the inside and out, and repairing the gel on the bottom. Handing this boat off to anyone will be very hard for me. I keep reconsidering and want to do it all myself.

The decision on the final finish has been hard. I’m still waffling. Paint, gelcoat, nonskid, or a combo.

Here is my problem.
The current gelcoat was from the 80’s so it’s an almond color. I hate the almond and want white. Ideally everything white with the sides seafoam or teal. It will match the white Suzuki. The hull bottom will be abused because it will live on a trailer. I’ve been told paint or bottom paint will look like crap after the first year, gelcoat is the only way to go.

Option #1, The bottom of the hull is in good shaped and will only need minor gelcoat repair if I keep it almond. I would have to suck it up and paint the rest of the boat to match.
Option #2, I could re-gelcoat the bottom white but that will be more expensive
Option #3, I could paint the bottom with Awlgrip white
Option #4, bottom paint it white.
Option #5, I could leave the bottom almond gelcoat and paint the rest white with seafoam gunnels, would the shade difference be noticeable due to the different angles?
Am I missing something? Does Awlgrip hold up to trailering?

Here is what option 5 looks like....

I think I found a guy to do the finish work. He has over 30 years doing gelcoat. He gave me a good quote and will do it all in gelcoat. Does anyone have any experience using Todd from Palm Beach?

The bottom will stay almond and be repaired. The topsides will be white. The sides will be a surprise. I found a classic color I liked. I don’t want to look like it came off the assembly line last week. I’ve never seen a boat with this color. I’m getting excited!

*Edit* Do NOT use this guy! read the outcome.

My Awlgrip has been fine trailering for 8 yrs now.

Took a leap. I left her in the hands of Captain Gelcoat. This will be the first time in two years she hasn’t been parked next to my house.

In the mean time I will be working on the fiberglass tray for the leaning post and electronics insert for the dash. My place really needs a cleaning. The whole house is covered in boat.

https://store.americanmarinesports.c...13erws020z.htm

may be worth buying a leaning post tray... at this point of my build I'm over spending endless hours on building 1 offs if there are easily sourced parts online. to each his own though, rebuild is looking good.

Let the faring begin.

You wont regret sending the boat out for the gelcoat work. You will be on the water sooner. There will be that strange empty space on the east side of your house until you get her back. Don't let your wife plant anything, of course nothing will propably survive from the fiberglass fallout :p

Kracken like your truck!

Thanks, Looking good with the Seacraft behind it!

Does anyone know what year Everglades boats had this color? I bought the top from Marine Connection a year ago. It was surplus. I think it might be called Reef Blue. It’s a blue gray. I want to do the sides that color.

Here are the transom dimensions with The Bennett trim tabs an the A&J bracket. I should be good on clearance but she is going to be tight. Hopefully someone else can use this information and not spend time spinning.

I went to take a look at the progress this weekend and was happy. Todd had most of the interior fairing completed. He has been good to work with. The candy shell should be done 3 weeks from now.

I ordered the DF300APXW this weekend. I got it from Brian at International. He had the best deal anywhere. I’m trying to get it scheduled for June. I also have the A&J bracket showing up next week. This is starting to get real.

Looking good. Can't wait to see her done!

Topside gelcoat was sprayed today.

Thanks can’t wait

I hear you. I’m spending to much time on dry land.

More pictures this weekend. He had love bugs attack the wet gelcoat. Will take some touch up. Nice to see her all one color.

We had love bugs show up during our topside gelcoating and found if you let it set you could scrub them off with a green scotch brite pad and buff it out with compound.

She got color this weekend. Sanding and polishing this week.

Great looking color

Almost ready for Jewelry.

Very nice, time for "bling" :)

The bling is in boxes all over my house. Finishing the gelcoat is taking for ever. I’m hoping it’s done by Sunday so I can get it to the welder.

Tomorrow I’m working on a mold for a dash insert to mount the electronics and another mold for under seat storage.

Christmas in May. Like a kid in a candy store I bet.

Setback today. When I took the boat to the welder I had my shoes off, the non-skid was hot. I didn’t want it that dark to start with. I asked for a whisper of color, almost an off white. It started to grow on me, but being hot was a deal breaker for me. I asked him to redo it in white and add more non-skid particles.

I will lose a week. My self imposed deadline is looming. I’m starting to doubt if I’ll make it. The One good thing is that the welder had the same console and will be able to build off if while Captain Gelcoat does his thing. I have a time slot to get the engine hung that I don’t want to miss. My son is going to Coopers Town for a baseball tournament that I will not miss. The boat will have to take a backseat for at least a week. Wish me luck for a 4 of July maiden voyage.