Gelcoat Spot Repair & Blend (5-Step Service)

For minor chips, gouges, spider cracks, or pitting in isolated areas, typically no larger than one square foot.

During the quote process, we scan the hull using a calibrated color-matching tool to generate an exact RAL code based on the current tone of your gelcoat, not just the original factory color. This allows us to order a custom color-matched gelcoat that blends more cleanly with the surrounding areas. Once you approve the estimate, we charge for materials and place the order. When the gelcoat arrives, we schedule and begin the repair.

While no spot repair can disappear completely in all lighting or from every angle, this process ensures a professional-grade finish that’s durable, clean, and ready for long-term performance. Excess gelcoat is labeled and left with you for future touch-ups.

Step 1: We thoroughly clean the repair zone and prepare the surface using a rotary burr or abrasive wheel, grinding out the defect and feathering the edges to create a smooth transition into the surrounding gelcoat. Any cracks, pits, or loose material are removed completely before moving forward.

Step 2: We catalyze and apply Marine Coat One color-matched gelcoat using a fine-tip brush or spreader. For deeper repairs, we build the material in layers, curing each coat fully before applying the next. On the final coat, we add Marine Coat One Surface Prep Wax Additive to ensure a proper air-cured surface.

Step 3: After the gelcoat is fully cured (typically 24 hours), we level the repair with progressive wet sanding using 320, 600, 1000, and 1500 grit sandpaper, carefully blending the repaired zone into the surrounding surface.

Step 4: We polish the area using Meguiar’s M6732 Marine/RV One Step Compound, applied with a Griot’s Garage Random Orbital Polisher and a Pink BOSS Microfiber Fast Correcting Pad to remove sanding marks, level gloss, and lay down a protective wax finish. Once compounded, we wipe the area clean with microfiber towels and follow with Meguiar’s M205 Ultra Finishing Polish on a White BOSS Perfecting Pad to refine surface clarity and restore maximum gloss. All residue is removed with clean, dry microfiber towels.

Step 5: We perform a final inspection under natural light to confirm gloss, smooth transitions, and finish quality. Any necessary spot correction is completed before cleanup.

Products Used:
• Marine Coat One Color-Matched Gelcoat
• Marine Coat One MEKP Catalyst
• Marine Coat One Surface Prep Wax Additive
• Rotary grinder or burr tool
• 320, 600, 1000, and 1500 grit wet/dry sandpaper
• Meguiar’s M6732 Marine/RV One Step Compound – applied with Pink BOSS Microfiber Fast Correcting Pad
• Meguiar’s M205 Ultra Finishing Polish – applied with White BOSS Perfecting Pad
• Microfiber towels
• Foam brushes or spreaders
• Labeled touch-up jar (left with customer)

Pricing:
• Starting at $250 for repairs up to 1 square foot
• Final estimate provided after inspection
• Travel billed at $110/hour
• Materials billed at cost