Fairing the Hull of an Optimist Pram with WEST SYSTEM Epoxy

WEST SYSTEM Technical Advisor Greg Bull walks through the steps to plan, and execute, fairing the hull of an Optimist Pram with WEST SYSTEM Epoxy.
He begins by discussing the difference between fair and smooth. Then he determines the high and low areas of the hull by sanding with a long board. This spans over the lows so the highs are the only areas being sanded. Then he removes the remaining paint and uses a batten to guide him in marking the lows.
The next step is to begin mixing fairing compound. He mixes WEST SYSTEM 105 Epoxy Resin and 206 Slow Hardener until they are thoroughly blended. Then he adds 407 Low Density Fairing Filler to the epoxy until it reaches a mayonnaise consistency. He spreads this fairing compound into the marked low areas and levels them with a metal batten.
After the epoxy fairing compound has cured, he sands the hull with a longboard again revealing any remaining low areas. The process is repeated until the lows have been filled.
Once the hull is acceptably fair, he rolls a slightly thickened fill coat onto the entire surface. This gets another round of sanding. Any remaining pinholes are then spot filled with a squeegee, to force the epoxy into the holes.
He rolls four coats of neat epoxy (unthickened epoxy) onto the entire surface to seal the fairing compound and create a consistent surface for the final steps of primer and paint.
This was an extensive project for the size of the boat, but the process can translate to any size boat and any level of fairness.
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PRODUCTS USED
WEST SYSTEM 105 Resin
www.westsystem.com/105-epoxy-...
WEST SYSTEM 206 Slow Hardener
www.westsystem.com/206-slow-h...
WEST SYSTEM 407 Low-Density Fairing Filler
www.westsystem.com/407-low-de...
WEST SYSTEM Application Tools (Rollers, Squeegees, Mixing Sticks, Mixing Pots, etc.)
www.westsystem.com/applicatio...
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MORE INFORMATION
WEST SYSTEM User Manual and Product Guide
www.westsystem.com/wp-content...
WEST SYSTEM Epoxy Basics - Fairing
www.westsystem.com/instructio...
Epoxy Safety
www.westsystem.com/safety/
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CHAPTERS
00:00 Intro
01:05 Make a Fairing Plan
03:07 Surface Prep
04:04 Marking the Lows
08:13 Applying Fairing Compound
13:16 Repeat Process Until Fair
19:14 Preparing for Final Fairing
22:48 Applying Neat Epoxy
24:38 Primer and Paint
27:14 Optimist Pram Sailing

[@Chinchilla27150]

What an outstanding instructional video! I finally have a feel for what it means to fair a small boat. This process obviously requires exceptional patience. I faired my last small boat with neat epoxy (to get a bright finish), which was incredibly labor-intensive and difficult. The obvious visual indicators of high/low are a major advantage of this approach, and I suspect they make it much cheaper and faster than fairing with neat epoxy too.
I must admit that I was pretty shocked and disappointed that we didn't get to see the painted hull bottom at the end of the video! Great guide to the process, though.

[@KMURRAY1841]

This video was immensely helpful. West systems 407 fairing + 410 rolled finish combo is awesome. Thank you Greg!

[@TTM-GEB]

Very informative... BUT no mention of Amine Blush!!!

[@raw123yt]

Nice demonstration of all the steps

[@JayPalazzola]

This is a completely different way of fairing then I’ve ever seen especially with rolling on the clear and I like it, one question though, how long do you have to wait before you can sand in between coats?

[@truckstopmedia]

Curious about the straight edges you're using for fairing. Can you let me know where to source those?

[@mountdoomee]

Great video! Couple questions:
For the fairing, do you use the glass bubbles thickener for easier sanding?
Also, for your thin coats of epoxy before priming, could you not tint the epoxy for your color then just varnish after?

[@WestSystemEpoxy]

Hey there! We use the 407 Low-Density Fairing Filler for easier sanding. We tinted the epoxy for a more even base before painting it, but it's not necessarily required to tint before painting or varnishing. If you are aiming to have a clear (not opaque) finish, we recommend applying a UV-inhibiting topcoat over your epoxy. Lots of varnishes include UV inhibitors these days. If you need more info, you're welcome to contact our Technical Department and speak to one of our Technical Advisors! 👍

[@Nomadboatbuilding]

Is there a reason that you didn't use the notched trowel method for the initial fairig stage?

[@WestSystemEpoxy]

You certainly can use the notched trowel method for fairing as it is described in section 14.3.2 of our Fiberglass Boat Repair and Maintenance Manual (www.westsystem.com/app/uploads/2022/10/Fiberglass-Manual-2015.pdf). If you have minor fairing work to do this may not be the most efficient way to fair the surface.-Rachael

[@KMURRAY1841]

What grit was used in sanding down the final 410 coat?

[@WestSystemEpoxy]

Greg says he used 80-grit sandpaper, then 120-grit before painting.

[@KMURRAY1841]

Thank you for the follow up!

[@regkershaw]

Can this be used on aluminium boats ?

[@WestSystemEpoxy]

Hey Reg! Our 105 system with the fairing fillers can be used on aluminum boats. However, we generally recommend using our G/Flex rather than the 105 system for this application as G/Flex typically achieves a stronger bond to aluminum surfaces. The fairing fillers can be added into G/Flex to make it easier to sand. Let us know if you have any other questions! 😃