How to Fiberglass a Jon Boat

If you can minimize the noises aboard your boat, or at least minimize their transmission to the water through your boat's aluminum hull, you won't scare the fish you're after. Fiberglassing an aluminum jon boat will help make the boat quieter in the same way that a carpet quiets footfalls across a floor. A double layer of fiberglass inside and outside your boat's hull will isolate the sounds inside your boat and provide a surface that you can sand to a smooth finish.

Things You'll Need

  • 40-grit sandpaper
  • Orbital sander
  • 6-ounce fiberglass cloth
  • Scissors
  • Marine epoxy kit
  • Disposable nylon-bristle paint brushes
  • Fiberglass roller
  • 320-grit sandpaper
  • Palm sander
  • Paint
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Instructions

    • 1

      Sand the entire boat, inside and out, with 40-grit sandpaper and an orbital sander. Cut two 6-ounce fiberglass cloth panels for each end, each side and the bottom of the boat, using scissors.

    • 2

      Mix marine epoxy according to the directions on the epoxy kit. Apply a coat of marine epoxy to the outside surface of the left side of the boat with a disposable nylon-bristle paintbrush.

    • 3

      Press one of the fiberglass cloths that is cut to fit the side of the boat, into the epoxy, using a fiberglass roller. Repeat the process for the front, back, right side and bottom of the boat.

    • 4

      Apply more epoxy over the fiberglass, one panel at a time. Press the fiberglass cloth into epoxy. Apply epoxy over the whole boat. Allow the epoxy to cure, fully, and sand it flat using 320-grit sandpaper and a palm sander. Paint the boat, if desired.

    • 5

      Cut fiberglass cloth to fit all the interior surfaces of the jon boat. Mix more marine epoxy and apply the epoxy to inside of the boat, beginning with the left side. Again, apply fiberglass cloth and press it into the epoxy. Continue until the interior is covered with a single layer of fiberglass.