Sailboat Hull Repair Guide

Introduction

A dent or hole in your sailboat’s hull can feel like a significant issue. However, if your hull is made from fiberglass, you have repair options. This guide will walk you through the process of repairing a fiberglass hull.

Step One: Preparation

Preparation is crucial before starting the hull repair process. Here’s what to do:

• Clean the affected area thoroughly and remove any wax. Rinse with fresh water and let it dry to ensure a debris-free surface.
• Gather essential equipment, including a respirator, an air-grinder with a sanding disk, a fiberglass mat, acetone, an electric buffer, safety goggles, gel coat, fiberglass catalyst and resin, a stir stick, and basic accessories like buckets and rags.

Step Two: Grinding

Wear your safety gear, including a respirator and goggles. Use a 36-grit sanding disk to grind down the damaged area. Sand the edges to create a slight slope, increasing the surface area for better adhesion.

Step Three: Fiberglass Repairs

Fiberglass repair can be straightforward if you follow these steps:

• Cut enough fiberglass mat to cover the damaged area, leaving about ½ inch overlap. Continue cutting additional layers, expanding the coverage by ½ inch each time until you match the original thickness of the fiberglass.
• Mix catalyst and resin as per the instructions on the label. Use a stir stick to ensure proper blending.
• Apply the fiberglass mats, starting with the smallest. Use a felt roller to eliminate air pockets and ensure even application. Repeat the process with subsequent layers, finishing with the largest mat.
• Allow sufficient time for the fiberglass to harden completely.

Step Four: Finishing the Hull

Once the fiberglass has hardened, sand it smooth and apply the gel coat. Finish by adding a protective wax layer to shield the hull from future damage.