GEL COAT REPAIR
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Gel coat is essentially pigmented polyester resin. First we start the repair by spraying or brushing about 20 mils of color-matched gel coat onto the waxed backer. Then we check the gel coat thickness with a toothpick; 1/32 is about 30 mils.
When the gel coat kicks, wet it with polyester resin and lay-up the first two layers of mat and one layer of cloth, compressing them against the gel coat and working out all voids and bubbles with a resin roller and/or a squeegee.
We let the first three plies kick, then lay up four additional plies until the repair is flush with the interior surface.
To get the proper finished look, cut a rectangular piece of mat and one slightly larger of cloth and apply these over the patch, smoothing them with a squeegee and seal this top layer with a plastic or PVA to allow a full cure.
Finally we remove the backer from the exterior surface, fill imperfections in the new gel coat with gel coat paste and allow it to cure fully, clean the area around the patch, and then finally sand if necessary and polish the repair area to a brilliant shine.
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