How to Remove a Gelcoat Using a Router

Gelcoat is used as a protective outer coating for numerous applications. The substance is generally applied to boats and kayaks or other water vessels. When scuffed, left out in the sun or through contact with water over long periods of time, the gelcoat can become worn, cracked or blistered. When this occurs you should remove then reapply the gelcoat. A variety of techniques can be used to remove gelcoat from water vessels. Using a router with a grinding wheel is one such method.

Things You'll Need

  • Router
  • Grinding attachment
  • Safety glasses
  • Mask or respirator
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Instructions

    • 1

      Clean away any dirt or debris from the hull of your vessel. Dry the area thoroughly with a towel.

    • 2

      Put on safety glasses and your respirator or mask. Ensure that you're in a well-ventilated area. If working on a kayak hull, it's best to remove gelcoat outside.

    • 3

      Attach the grinding wheel to your router. As all routers vary in design, the attachment process will vary. Consult your instruction manual for specifics.

    • 4

      Turn on the router and place the grinding wheel flat against the vessel's surface. Move the wheel on the surface side-to-side or up-and-down, touching the surface lightly to remove the gelcoat. Do not use too much pressure or you can grind into the hull.

    • 5

      Brush away the dust from grinding to clear the workspace every so often. Continue grinding as in Step 4 as needed until your gelcoat is removed.