Instructions on How to Repair the Gel Coat on a Kayak

On fiberglass or Kevlar kayaks, the gel coat layer, the smooth outside finish, protects the composite fabric. When damaged, it reduces the boat's stiffness, allows water to penetrate into the composite and exposes the composite to damaging UV rays. To make your kayak last longer, repair any damage to the gel coat. While getting a cosmetically perfect finish requires experience and skill, almost any handy person can make a functionally perfect repair. A repair takes several hours with a day of drying in between.

Things You'll Need

  • Masking tape, 2-inch and 1-inch
  • 80-grit sandpaper
  • Acetone
  • Rag
  • Gel coat
  • Mixing cup
  • Mixing stick
  • Paintbrush
  • Plastic squeegee
  • Plastic wrap
  • 120-grit sandpaper
  • 220-grit sandpaper
  • 400-grit wet sandpaper
  • 600-grit wet sandpaper
  • Bucket of water
  • Buffer
  • Microfinishing compound
Show More

Instructions

    • 1

      Surround the damaged area with a layer of 2-inch masking tape. Keep it 1 inch away from the damage. Add a second layer of 1-inch masking tape 1/4 inch away from the damage. The masking tape prevents the repair from dripping onto a original surface.

    • 2

      Sand the damaged area with 80-grit sandpaper until you reach the fiberglass or Kevlar. Avoid sanding into the composite, especially Kevlar, because it "fuzzes up" when sanded. Sand all the stress lines down to the composite that radiate out from the damaged area.

    • 3

      Replace the 1-inch masking tape with a fresh layer if you damaged it during sanding. Clean away any sanding dust with a rag soaked in acetone.

    • 4

      Mix enough gel coat to cover the repair according to the manufacturer's instructions.

    • 5

      Paint on enough gel coat to cover the repair to the same depth as the original gel coat. Use a plastic squeegee to feather the edge of the gel coat.

    • 6

      Remove the 1-inch masking tape when the gel coat starts to harden.

    • 7

      Place plastic wrap over the gel coat. To cure completely, you must prevent air from contacting the gel coat. The plastic wrap prevents air contact and can also create a smooth surface if you apply it carefully. Let it dry completely, usually overnight.

    • 8

      Apply a new layer of 1-inch masking tape around the repair. Keep it 1/8-inch away from the new gel coat.

    • 9

      Sand the new gel coat smooth and even with the old gel coat's surface. Start sanding with 80-grit. Follow with 120-grit and then 220-grit until the surface feels smooth.

    • 10

      Sand with 400-grit wet sandpaper followed by 600-grit wet sandpaper. Keep a bucket of water nearby to dip the sandpaper every few seconds. The water cleans the dust out of the sandpaper.

    • 11

      Buff the surface to a glossy finish using microfinishing compound.