[alarie]

For small repairs like you are talking about, we use a siphon gun (SATA gun is what we have) with a large tip to spray gelcoat without problem. Pressure pots are great and do work better, but they are not practical for the hobby guy to own and use. With either gun you will have to sand, so it is really no big deal how the spray job comes out. We get some pretty nice finishes with this method, and generally start sanding with 320.

Mix:
Gelcoat, 20% Duratec Clear High Gloss Additive (not the clear high gloss finish, which is thicker), and then thin with MEK 5-10% to get a nice spray consistency.

Method:
Spray 1 light coat without wax and let kick until firm. You can then pinhole your surfaces-we use a foam brush stripped of the foam cover, leaving the flexible plastic undercore which you use as a squeegee. Mix a small batch of kicked, unthinned gel and swipe it into the pinholes. You can be pretty neat with this tool, so don't make a mess.

Once pinholed, go back and spray 2-3 more thin coats over the area, adding wax to the last 1-2 coats so that the surface will dry. Wait 10 minutes or so between coats (kick separate batches of gel from one "master" batch that you mix at the beginning.) We get nice results with this method and often do not sand the surface in non-critical areas.

I am planning on gel coating the inside of my project 20 with this method, and will likely not sand any of it.

You can also use the same method for great non-skid application. Spray your surface so that the color is down and you have good coverage, then mix gel as above, thin it a touch more, and add your non-skid (we use Awlgrip particles) and then spray one SUPER LIGHT pass over the area. Too much spray and you will just bury the particles under the gel, so go light and you will like the results.

Good luck and email if ??
Peter