69' Whaler Nauset

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robertw007

Cadet
Joined
Jul 22, 2025
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As previously mentioned in another thread I will be potentially rebuilding if not, refinishing and modifying my 69' whaler nauset. I absolutely love this boat so whatever has to be done, so be it.
Rebuild will be done if I'm waterlogged. In the next few weeks I'll be removing the motor to go weigh the boat, that'll tell me if I've got an obese boat or not.
I've got my gantry built and chain block hoists are coming in tomorrow.
I plan on repairing two spots on the hull with 1708 and poly resin, adding two small boxes at the rear. One for battery, one for storage both with flip top lids.
Also have to install the two brass tubes for splash well and drain plug.

I have a question on gelcoat application. Originally the plan was to use a brush and solvent resistant rollers to apply, but I'm thinking more on spraying instead.
If I decide to spray, how do I know how much to thin the gelcoat? What's the best product to thin with?
I'll be using FGCI exterior gelcoat.
 
Scott Danforth

Scott Danforth

Grumpy Vintage Moderator still playing with boats
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I suggest duratec 904. makes gel spray like paint. FGCI sells duratec . the boat in my sig was sprayed with FGCI gel and 904
 
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MikeSchinlaub

Petty Officer 1st Class
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Jan 14, 2025
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You want a big needle too, at least a 2.0. Spray it like a high build primer, about 5 coats. Then, even if it's gummy on the surface, you can sand and buff it.
 
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robertw007

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I've got most everything ordered. I did speak to FGCI about the process of spraying but I might have mis noted. Scott, you mind double checking me?

Build up coats will be 1:1 duratec 904 and fgci gelcoat. I'm in South GA, pretty muggy and I will be doing this outside, under a metal carport with plastic sheeting hanging down in the front and rear to create an enclosure. Best I got.
Should I use the mekp 925 or the regular? Based off my excessive reading and limited knowledge, I'm thinking 1.5% due to the heat and humidity?
I'll make 3 passes or approx 18-20 mil thickness and let it dry. Sand smooth with some 500 grit?
Another pass of 3, dry, sand.
Then the final pass gets 3:1 ratio gel/duratec. Should i add wax additive in that final coat?
Then sand 500/800/buff.

For the inside, same thing.. but in certain areas of the deck I'll be adding a sandpaper like texture additive in the final coat. Should it also get the wax on final?
 
Scott Danforth

Scott Danforth

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you have to do a few test sprays. I was close to 1:1

you do not need wax if you are using duratec.

no need to change ratios, you wont have time.

I sprayed out in the open, which really sucked because it was love bug season in Florida (March / April)

you will be about 1% and you need to have everything pre-measured and iced. you will need a helper to mix and hand you a cup to pour into your gun.

if you are going to spray between now and about October in south GA, you should plan on the gel kicking in the gun if you are not fast enough, and have a fire extinguisher handy. seriously, have a fire extinguisher handy.

you will spray all 3 to 4 coats at once. by the time you get from one end of the boat, you will then start over..... no need to spray 3 coats, sand and spray another 3 coats unless you are changing colors.

I did between 3 and 4 coats for each color, then sand and buff.

for sanding, I did 220, 320, 400, 600, 800, then two stages of buffing

read pages 1 and 2 of this thread regarding taping off, etc. https://www.boatdesign.net/threads/gelcoating-the-whole-boat-down-to-the-waterline.61694/

read pages 8-16 of the build thread in my signature for sanding, spraying, sanding, buffing
 
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robertw007

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Jul 22, 2025
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Scott Danforth said:
you have to do a few test sprays. I was close to 1:1

you do not need wax if you are using duratec.

no need to change ratios, you wont have time.

I sprayed out in the open, which really sucked because it was love bug season in Florida (March / April)

you will be about 1% and you need to have everything pre-measured and iced. you will need a helper to mix and hand you a cup to pour into your gun.

if you are going to spray between now and about October in south GA, you should plan on the gel kicking in the gun if you are not fast enough, and have a fire extinguisher handy. seriously, have a fire extinguisher handy.

you will spray all 3 to 4 coats at once. by the time you get from one end of the boat, you will then start over..... no need to spray 3 coats, sand and spray another 3 coats unless you are changing colors.

I did between 3 and 4 coats for each color, then sand and buff.

for sanding, I did 220, 320, 400, 600, 800, then two stages of buffing

read pages 1 and 2 of this thread regarding taping off, etc. https://www.boatdesign.net/threads/gelcoating-the-whole-boat-down-to-the-waterline.61694/

read pages 8-16 of the build thread in my signature for sanding, spraying, sanding, buffing
Click to expand...
That's a cool paint job!
Is there any way to avoid needing the fire extinguisher? I imagine icing down the gelcoat and mekp helps.
Small batches about 8oz or less?
And on the mekp type, FGCI suggested the 925 version.. said it was hotter and would cure faster, I told him I was in 90+ degree weather as it is.. but he still recommended it. What did you use, just regular 9% mekp?
I'd like to get it done before October for sure.
 
Scott Danforth

Scott Danforth

Grumpy Vintage Moderator still playing with boats
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robertw007 said:
Is there any way to avoid needing the fire extinguisher?
Click to expand...
wait until temps are below 80. with the current warm temperatures of Florida and Georgia, if you mix a hot mix, gel can literally go up in flames due to exothermic reaction to the MEKP

I couldnt tell you if I used their 925 or the 9.
 
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MikeSchinlaub

Petty Officer 1st Class
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Jan 14, 2025
Messages
367
You don't have time for small batches. If you try that, what's left if the first will kick in the gun before you get the second sprayed. You need to spray a full cup at a time, and with those temps likely do a full tear down and clean between each cup.

Also, about your enclosure. That will have so much overspray that you won't be able to see pretty quick. My idea, cut a hole in the plastic on one end and tape a box fan in place, somewhere around chest to head height. Cut another hole on the opposite end and tape a cheap furnace filter in place. That will give you a bit of exhaust while allowing air to come in, but keep debris out.

I would also recommend a hooded tyvek with a full face respirator. Tighten the respirator harness over the tyvek hood to keep it in place.
 
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robertw007

Cadet
Joined
Jul 22, 2025
Messages
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MikeSchinlaub said:
You don't have time for small batches. If you try that, what's left if the first will kick in the gun before you get the second sprayed. You need to spray a full cup at a time, and with those temps likely do a full tear down and clean between each cup.

Also, about your enclosure. That will have so much overspray that you won't be able to see pretty quick. My idea, cut a hole in the plastic on one end and tape a box fan in place, somewhere around chest to head height. Cut another hole on the opposite end and tape a cheap furnace filter in place. That will give you a bit of exhaust while allowing air to come in, but keep debris out.

I would also recommend a hooded tyvek with a full face respirator. Tighten the respirator harness over the tyvek hood to keep it in place.
Click to expand...
Already with you on several things there brotha.Thank you. I've got a big warehouse fan, and a couple blower fans. Got the full face respirator, got the suit ordered. I was thinking I'd be doing a full tear down and cleaning, each cup anyway. I don't see it getting much cooler anytime soon.

I really appreciate the info gentlemen. I work in IT, but grew up on a farm so I'm not scared of some work.. or foreign tasks. It is nice to know what I'm getting into, I sure hate hindsight education.

Got the chain hoist in.. looking like I'm either going to rig up this little 70hp.. 5200 two minor issues and play a a few weeks, or go ahead and strip her down and get ready.

I'm thinking the former. Give it some time to cool down a piece, rather not have my new paint gun catch fire in my hand lol.
 
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