How to Repair a Fiberglass Drift Boat
A basic law of physics is that if a boat has a hole in it, it will sink. Occasionally drift boats sustain damage from rocks and other debris hiding in the water. A small hole or other damage does not mean that the boat is dead, however. Fiberglass bonds to itself wonderfully, making repairing fiberglass quite possible. Try fixing your damaged boat before giving up on it.
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Things You'll Need
- Hard object
- Saw
- Dewaxing solvent
- Scrub brush
- Grinder
- Paint brushes
- Acetone
- Rag
- Paste wax
- Cardboard
- Scissors
- Duct tape
- Fiberglass mat an cloth
- Resin and catalyst
- Gelcoat and catalyst (optional)
- Disposable buckets
- Resin roller or squeegee
- Electric sander and various grits of sandpaper
- Paint (Optional)
- Wax (Optional)
- Polish (Optional)
Instructions
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1
Remove the boat from the water. If the damage is below the water line, allow the boat to dry fully.
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2
Tap the area around the damage with a hard object to determine the extent of the damage. Damaged fiberglass makes a dull sound when tapped, while good fiberglass makes sharp sounds.
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3
Cut away the damaged fiberglass.
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4
Wash the inner hull around the hole with a dewaxing solvent, then with acetone.
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5
Grind the area a few inches around the hole to help ensure a good bond. If you grind slightly below the surface you will be able to create a patch that is flush with the rest of the boat. Remove any dust and wash the area again with acetone.
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6
Apply a generous coat of wax to the outer hull around the hole to keep any resin drips from sticking.
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7
Cut a piece of cardboard a few inches larger than the hole. Tape it securely to the outer hull, then wax the inner surface to keep the patch from sticking. The cardboard forms the backing for your patch.
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8
Cut several layers of fiberglass cloth 1/2 inch larger than the hole. The exact number depends on the thickness of the boat hull. Typically you want one piece of fiberglass for every 1/32-inch of thickness.
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9
Cut six pieces of fiberglass mat, three of them 1/2 inch larger than the hole, the other three 1 inch larger.
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10
Mix a batch of gelcoat-thickened resin with its catalyst. The instructions on the product that you use will give you the exact mixing ratios. If your repair is below the waterline, skip this step and use epoxy resin instead of polyester resin.
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11
Brush a layer of catalyzed gelcoat on the inner waxed surface of the cardboard. Allow it to fully cure until it is no longer sticky.
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12
Mix a larger batch of resin and catalyst in a new bucket.
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13
Brush a coat of the new resin onto the gelcoat.
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14
Apply one of the smaller pieces of fiberglass mat into the resin and tap more resin into it, saturating it fully and removing any trapped air bubbles.
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15
Apply the second and third smaller pieces of mat in the same way, saturating each with resin.
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16
Switch to fiberglass cloth and continue building layers of fiberglass and resin until the patch is flush with the inner hull.
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17
Add the larger three pieces of fiberglass mat, one by one, on top of the patch.
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18
Allow the fiberglass to cure overnight.
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19
Remove the cardboard and fill in any imperfections to the outer hull with fresh gelcoat.
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20
Sand the inner and outer sides of the patch smooth.
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21
If desired, paint, wax and polish the patch.
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Tips & Warnings
Always use proper ventilation when working with fiberglass resin.
Wear protective gloves, goggles and a dust mask when working with fiberglass.
