Apply and Refinish New Gelcoat over old on a Contessa 32 (ReGelcoating 101)
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- เผยแพร่เมื่อ 22 ม.ค. 2025
- Tired, old, thin and UV damaged gelcoat can be fixed my applying new Gelcoat over the old, here is show you one way to do it on a Contessa 32. If you plan to regelcoat your boat I hope you like sanding!
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If you have enjoyed this video and/or learned something you can now buy me a beer using the link above to make a donation to the channel. If I end up with more beer tokens than I need then I will put your donations towards a better camera, lighting and other equipment so it ultimately benefits you the viewer. I don’t do Patreon, I don’t sell T shirts but you can help support this growing channel. Thank you
My thanks to the owners of these boats for giving me permission to create this content based on the refit of their boats.
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About Me
I run a small business called The Solent Boat Butler and spend my days repairing, maintaining and refitting sailing boats (often Contessa 32’s due to my long experience with them). I'm mostly in the central Solent area of the UK. Being a cruising and racing sailor with many thousands of inshore and offshore sea miles logged I like to think that I bring a great deal of real-world experience to my work and help many new (and not so new) boat owners to improve and maintain their boats. When I'm not fixing boats I also provide some own-boat sail training, help owners with deliveries, provide pre-purchase inspections and deliver consultancy services to those that are refitting their own boats for cruising or racing.
Facebook - thesolentboatbutler
Instagram - @george_the_boat_butler
Instagram - @refitandsail
Website - www.solentboatbutler.co.uk
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Disclaimer
I hope that viewers both enjoy and learn something from my videos but please remember to take the appropriate precautions for any DIY refit works you undertake with appropriate PPE and the correct tools for the job. If you are in any way unsure as to how to go about a project or are unsure if something on your boat is safe please consult a professional. I don’t necessarily show every step of how to do a particular job so only take on a project if you know exactly what you are doing or consult a professional, I accept no liability for errors or omissions in this video, it is for entertainment purposes only.
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Music credits
Intro Music: Bensound.com
Other Music: epidemicsound.com
![HOW TO SAND and BUFF GELCOAT -sunfish sailboat restoration- [Part 3]](/img/n.gif)
The tip of using the marker for you guide coat is brilliant. Thanks for that. Very informative video.
I'm a little speechless, Honestly I was waiting for you to drop the ball in process, that not only never happened but you went beyond industry standard, I've worked for several industry leaders and their finishing techniques fall short of your process, seriously impressed.
Thanks, that’s a appreciated compliment.
Didn't realize Gel coating was so labor intensive....but it looks great when completed and well protected (that area). Thanks for the lesson...great job!!
I would appreciate a separate video about polishing with the machine as it’s something I always seem to make wrong. Thanks for the good show - I did not skip any second of the sanding part :)
Well done!
The information and techniques you've presented match that of an American I've been following for a dozen years or so, so you've added to my confidence that I can do this when the time comes.
And ... what? No "Oh Glorious Sanding" videos? 😁 That's okay. There's a Danish DIYer who provides me with enough of those.
Thanks for producing this very informative video George, and appreciate the top tips at the end. Never leave the sanding out, it’s like lulling others into a false sense of security 😂
The sanding….. oh God the never ending sanding….. 😆
Thanks George, very helpful and informative. Yes, I did watch all the sanding!
Well that makes 4 of you, well done 😆
I did skip forward on the sanding but as I have done so much sanding over the years I felt that it was OK to do so, It also brings back bad memories, LOL.
That’s fair 😂
Another fantastic video George. Thank you.
I have to do this to the topside of my boat...and it's long overdue. Great work by the way. I now feel confident on how to take the work on. Just as an FYI, in the states (US) most of us non-professionals use the roll-&-tip method. We roll on the gel coat and then use a very good fine brush to smooth everything out. Because we're out of shape are absolutely obsessed with NOT sanding this much by hand. Some guys who do this dockside for a living, are really good at it. Your final product is better than what we get, so I'm thinking I'll split the baby here and do more sanding, along with the roll and tip.
i have done both methods, but not very large areas. I agree anything to cut the time down on sanding is a blessing, but i think brushing only gives a much thicker final layer of gelcoat. I suppose if this is true we could just roll on more layers to make up for the difference. I need to do all my topsides as well and am seriously dreading all the sanding. I think for a single person this is a two week project easily.
I do enjoy a good sanding in the evening. So yes, still watching. :)
Haha, that’s at least one viewer all the way though then 😂
A great video on gelcoast repair....for the first time I understand it....thank-you!
Glad it was helpful!
Thanks for explaining gel coat application. Very cool and looking forward to trying.
Awesome information on how to properly paint on gel coat. Im ready to start my 1987 Four Winns 170 Horizon. Thanks so much.
Nicely led through, no shortcuts eh with the grades ! This will inspire people to up their refurb game , thank you .
Thanks
Fantastic job! Thank you for the tips!
Such well presented and educational. Thx you so much. Awesome quality workmanship!
Outstanding job!
I hate gelcoat. But what I hate more is it's the best option.
I like it.. it looks like an epoxy paint.
lol....well said.
top VIDEO, have seen it from the begginning until the end, a lot of work, when the result shout look like proffessional work. Thank you for all the Tipps of your VIDEOS.
That is totally awesome!
Great channel, thanks for all of the interesting content.
Sent you two beers from Florida!
Sean McGee
That’s very kind, many thanks Sean!
Outstandingly beautiful job!
I love sanding gelcoat. I could watch it for hours! And great work!
I think you need professional help 😂
full of good data about applying Gelcoat on a boat ! Nice one.
Thank you George for a very informative video. I have a big job coming up so will adopt your techniques.
I'm back for a refresher course from 8 months ago since I brushed my first layer of gelcoat onto my modified helm today. First I was surprised at the depth of the brush-strokes. I was expecting the gel to level out somewhat. Nope. Then I figured I'd have to sand the strokes out but by watching this video again I see that the strokes are typical and to brush succeeding coats in opposing directions. Whew! Glad I checked back with you. I'm using waxed gel so I have to remove the wax between coats.
What a hell of a job. Nice video.
Thanks! Makes me want to get parts of my boat done.
One of the best I’ve seen. Thanks
I have watched hours of videos and got more confused on what product to use, this one actually covers exactly what I need to do! I have an ancient Invicta 26 and the top side is horrible, I can see daylight in parts from the inside. So I tested gelcoat on my repaired Laser dagger board and that was a disaster, I didnt realise the gelcoat remains tacky (I didnt know its meant as a mould product where there is no oxygen) so then tried PVA to dry it. Anyway made a mess of it with runs and dead flies, grit, etc. Ended up sanding virtually everything off, gave up and just painted it!
So this gives me confidence to have a go on the boat with Gelcoat so I get some depth in the material that I wouldn't with paint.
Pleased it was helpful, best of luck with the project.
@@RefitandSail Reading below I realise I used the wrong PVA (mine was from Wickes so is wood glue), it certainly allowed the gelcoat to dry but what a mess! Sanding it off clogged up the sanding belt in no time and I ended up removing virtually everything I had applied.
@@simonroyle2806 example of the pva www.ecfibreglasssupplies.co.uk/blue-gloss-pva-release-agent
That was a verry informative video. Thank you for providing your know how. Now I have some sanding to do.
Enjoyable video. . . A lot of process/graft it seems. The results look great. I recognise the pub in the background 🙂 . . . Jack Rolfe's favourite!
Haha, indeed it is, well spotted! I go there occasionally
I am completing a gel coat job on my 23' RIB, radar bar. I'm continuously watching video's to evaluate the process I used to get to the point of block sanding and polishing. The only difference in my application is I used a mini roller, instead of a brush. Thanx for the education..
That's a bit of alright! nice finish!
I’m not sure of your views or experience with rolling 2K paint on topsides, decks and cabin sides, but it’s becoming a popular option for both budget refits and the fact some yards don’t allow spray painting these days. I’d be very keen to see you demonstrate the technique in an upcoming video, cheers.
Yes you can get some really excellent results with some of the recently produced paints and if you get enough on it can be polished back to an excellent finish. I have a couple of hull repaints coming up but they will probably be sprayed.
This video helped me SO much. Thank you! The methods for cutting and polishing especially.
Glad it helped!
Very helpful and I an especially like and thankful that you take extra care of the environment by using a dust extraction even when dry hand sanding. Pro tip using the marker and aceton
Great video on Gelcoat polishing!
Enjoyed the episode….miss the Hamble, The Jolly Sailor, Whyte Hart….have some gelcoat work to do on my cat here in Florida, so a timely video! Thanks, Andrew
Thanks for this video. I have a very small area of gel coating to do to repair a damaged area on my boat, so this has given me a better idea of what to do. I appreciate the work you put into these videos and your sharing your knowledge and expertise.
Glad it helped
Hi George, fantastic tutorial! It's truly inspired me to take the leap with my Westely Konsort restoration. Would you mind sharing the Gelcoat paint product you used, along with the supplier? I really appreciate how you pointed out the off-white color, as it's exactly what I'm looking for. I'm based in the UK, so if you're happy to share, I can use the same supplier. Thanks so much in advance! Loving the channel-there's so much more to watch and learn. Keep up the great work!
Great video on re-gelcoating coachroof
Suggest you wear knee protection in future! I speak from experience😉 I went for the paint option on my R36, but everything, only the toerail was left on. The deck and coachroof were in v poor shape. Four epoxy primer coats, 2 high build, 2 normal, 4 two-comp topcoats. Has lasted really well, but even if it gets scratched, repair is easy.
Thank you so much for this tutorial. Ready to get cracking on my poor gel coat.
It's hard to accept you as a pro when I see you crawl around with your bare knees on a non-skid surface without knee-pads. It's not the skin of your knees that gets damaged so much as it is damage to the knee-joint itself. Your career will be shorter without pads. Taking the gel-coat above and below the outside and inside corners results in a much better look for the boat. Nice change. That second coat was cute...paint porn, complete with appropriate music. This video is informative and so are your responses to many of the comments. I appreciate it. I know...that don't buy beer.
No worries about the beer-tokens, that’s optional but always appreciated. I do normally use a kneeling pad (as I don’t like having pads attached to my knees. Fortunately the non-slip on this deck is very worn and due to be replaced (likely in a future video). Thanks for the comment.
Forget the knee pads, but sanding those poisons without a face mask is so smart. That will retire him earlier. I could understand if you do this once a year in your own boat, but if you do this for a living, that I can't comprehend.
I AM watching the sanding because i wanted to know how you worked your way around gelcoat and sanding. As it turns out I have been using the almost exact same procedure. Applying the gelcoat by brush, sanding with 120 grit at the very uneven spots by hand and using an orbital sander with 320 grit on the plane surfaces - but i only gave it four coats and I haven´t sanded through yet. Next time I think that five coats is safer. Thank you for posting this at the right time 😂
4 should be plenty of applied thickly but 5 gives a bit of margin for error in the sanding so no harm. I tired to do it with 3 coats once and it’s just not enough, 4 minimum, 5 ideal.
your idea of doing a small test is a great idea thanks mate !
Well worth doing if it’s your first time using gelcoat
amazing result, nicely done!
Great video
Very informative and concise
Really appreciated this post
Glad it was helpful!
Yes, watching the sanding. At 32:!7 quite some flex in that deck.
I think the Timelapse makes the deck look like it’s flexing more that it is somehow. It’s solid laminate (not cored) + stringers so there is some flex but not excessive.
Great tip on the practice board gel coat!
Great video, I want to re gel coat the cockpit of my Westerly. Your video clearly explains what I need to do but just the thought of all that sanding makes me want to cry.
That’s a pretty standard westerly gelcoat issue unfortunately, mine is the same.
Still watching you sanding but glad it’s not normal speed 😂
Thank you! Best video ever😊
Thanks!
Thank you very much! Great vidéo!
Fantastic finish, I didn't see any water for the wet sanding. Thanks for showing us.
Water was in the bucket, only need enough to lubricate the abrasive.
Thank you for making these videos. You make it look like I can take on some of this work myself. Current project is a 1965 Islander 33. Thanks again!
Thanks for the comment, best of luck!
Great vid. Lots of work in the finish
Muito obrigado pela ótima aula sobre gel coat.
Abraço do Brazil
Thanks for this video and explanations.
On my last boat i gel coated the whole deck area. Current boat i painted it with a 2 part poly. Love the durability of gel, but it is tough work and time-consuming.
That is one of the best videos I have seen:- really good, clear explanations and full of great tips ( that professionals tend to keep ‘secret’ !)
It also demonstrates why some apparently ‘simple jobs anyone can do ‘ do cost real money. Why? Because these guys have learnt their skills over many,many years and many almost identical jobs.
Well done -nice job!!!
Wow, thanks! Pleased you thought it was good
First class advice, first class job and first class video. Thank you.
Hey George, really enjoyed this video and yes, I enjoy the sanding
If you enjoy sanding do you want a job? Haha
Very helpful. I’m about to do some gel coat repairs on my boat. So this was helpful to me. You used gel coat, which surprised me. From what I have ‘read’, I would have thought ‘flowcoat’ is for use like you used it.
Flow coat is just gelcoat with wax in it that rises to the surface when curing so you don’t have a sticky finish.
Apply a thin CA glue to the base of the brush and let it cure. Then you won't get any hairs in the new gel coat. Model airplane folks use this trick all the time.
Great, informative video. Thanks
The concave surfaces can use sandpaper wrapped over a paint roller. A totally ignored tip I have given before on TH-cam. But the Beauty of blocking can also be done in the concave.
There’s a trick that the Chinese painters use for pretreating the brush. Squeeze adhesive into the base of the hairs inside the metal clamp. Let dry and the hairs will not get pulled out. So you don’t need to pay for expensive brush .
I have a project Pearson needing a gel coat overcoat. I am thinking of smoothing out to remove brushmark, with sponge paintbrush (paintsponge?)
Great George - beginning to end very informative and helpful incl final tips. Thank you for sharing such insightful content! BW Ulrich
Thanks for watching and the continued support!
oh glorious sanding
A ‘mads’ reference?
Some say he's still looking for that elusive black sharpie. Fun fact, green is actually harder for the human eye to see. In graphics "RGB" (Red/Green/Blue primary colours) is generally set as "565" so the green level is higher to compensate for natural human eyes vs graphics on a screen.
Interesting, thanks.
I never knew that about Green, will stick to black and blue maybe. Thanks for the tip!
As always...well done!!
Thanks
Great how to vid. Thanks.
Great video as always, thanks for the info.
Thanks
wow, what a job.
A comment if I may, at 22:55 you are showing the sander attached to the hover, however if you look at the sole of the sander, it is perforated in order for the hoover to do the job, but that again requires the sanding paper to have matching holes, otherwise the dust is just going to blow all over. When the perforation in the sole of the sander and the sanding paper are matched, the hoover removes almost all of the dust.
I use sanding mesh rather than traditional sandpaper that needs holes. That may not be obvious in the video (although I do show the sanding media I think). Google Mirka Abranet or Mirka autonet and you will understand (other manufacturers make similar). Haven’t used traditional “sandpaper” with or without holes for years.
Thanks for the comment 😁
Ok thank you, that makes sense@@RefitandSail
Excellent. TFS.
Haha, if you can take off your t-shirt in UK, even while working, the weather must be superb.
@@peterk4134 that was a pretty warm day, a stark contrast to today!!
Can you say something about how you prepped the surface before you brushed on the gelcoat?
Excellent thankyou.
I understood what u meant no worries and thank you
Watched it all. Including the sanding.
I would like to buy "knees" like yours to do this job in my boat !!! :) great job , thanks
You don’t want my knees, but a kneeling pad from the garden centre makes it all a lot more comfortable!
Have you done a video on repairing gel coat cracking/crazing that occurs as hull's age?
Have done some gel repairs on other videos (within project Lottie series) but I can’t recall exactly which video
Hi George, thanks for the tutorial. At the end was the new gelcoat sticking out more compare to before, I'm asking you because I will love to regelcoat my Westerly and I was wondering if it was possible to do it in the same way.
Cheers
It looks good, wouldn’t say it stands out because I chose to use a slight off-white. It just looks shiny and new. I’d like to do my Westerly but I’m not sure I have the time as she’s a lot bigger than this co32. Unfortunately the gelcoat used by westerly in the 80’s wasn’t the finest quality so lots of boats have problems.
Yes still watching😂
How bizarre, as a boat builder of too many years to mention, your method and system is Exactly the same as mine. (even the gelcoat supplier!)
I guess the only way I differ is that I use a 3" spreader to apply the top coat, which tends to give me a flatter finished surface. So when I start the sanding process I can use 240g.
Then 1000, 1500 and then 3m compund.
Good job.
Well that’s good to hear. Thanks
Hi, I am just about to re gelcoat the transom on my yacht, do I sand between coats or do I leave it to the end if I apply the coats whilst still tacky.
Cheers, looking forward to the live stream 😊
Apply all the coats then sand, you need to build up the thickness of the gel so it can then be sanded back and refinished
thanks for the video, I have not worked with a gel coat, After watching a few times I noticed that the gel coat was used to get a smooth finish by removing most of the coats of gel coat, In autobody we want the coatings to remain as level and thick as possible since it is the protective coating and allows for a sand and recoat of just the finish layer. would it not be easier and cheaper to use resin and fiberglass as a paste to create the perfect flat surface, using the guide coats on the fiberglass will allow a lot less sanding of the gel coat while leaving more of the protective layer this also removes the chances of breaking through the gel coat in the less than perfect areas?
Have you used (thin) high viscosity cyano acrylate glue on cracked gelcoat prior to the gelcoat process? Ive had good results in light stress to moderate stress crack repairs...it seeps well into the glass fiber voids repairing the area.
Liked so I subscribed. Question. I don't know gelcoat but is there a surface hardness that is harder than underneath? Like a shell. Would a roller have been faster and smoother than the brush? I'm polishing the gelcoat on a 35 year old boat in Ont Can. This boat has never seen the UV intensity of the tropics or salt water. I'm starting with 3000 on a 5 inch disc sander with a half inch foam pad to fit curves and it takes the stiffness out of the disc sander pad. I use lots of water to keep the sanded material washed off. I then move up to 5000 then a buff to finish. In a few spots I'll have to grind cracks and fill. You and your apprentice sure did a lot of sanding. Kudos to you and him.
yupp, still watching the sanding :)
That makes you the third person 😆
Yes, I’m still watching you sand. You make this look fun, but don’t try this at home my knees hurt just watching you work.
What was the green stuff you apply before sanding?
Thank you so much George! This will greatly help refitting my 35yo deck. Are you tackling the anti-slip in the next video?
Not the next video but will prob be in the future
Great vid, thank you. How would you fill in a low point or depression on the surface? Would you put extra coats of gel coat only on the depression to build it up?
It would depend on the shape/size of the damage/depression. It’s likely that would use fill and fair with some white gelcoat filler prior to putting the fresh gel on top
I ve watched this video a few times and it is a great tutorial. It s really improved my finishing work. My 1972 Buchan 37 could use a gelcoat spruce up for sure. I m curious why so many coats, tho. You say that you abraded with 80 grit and from what it looks like thats a rough up and not a sand down. So theres a good base there. Brushing gelcoat makes for a fairly thick coat. It seems to me that 5 coats is going to add a lot material. Can you comment on that, please?
Pleased you liked the video, could possibly get away with less coats but it increases the chance of sanding though to the original gel which is a total pain as you then have to rebuild the new gel to refinish again. With 5 coats the finished layer is probably only 0.5-0,8mm so not that thick but a lot thicker than paint so minor scratches down the line can be sanded out.
Ok....a bit of latitude there. Thanks for quick reply.
Good vid!