Removing boat gelcoat - 1965 Boston Whaler 16'

[fishingfrenzy]

I currently have a 1965 Boston Whaler 16' in need of TLC and some foolish dreams. Before I begin, I am aware of the Boston Whaler specific websites, but folks in those places rarely dig deep into their classics. Thus, I turn to Iboats in search of knowledge.

You can see my gelcoat is dead and cracking below the waterline. I believe this is due to the old gel being layed on too think; this seems to be a major problem in 60's - 70's Whalers and Bertrams. The cracks do not appear to penetrate the gelcoat.

To do this restoration correctly, I need to remove the old gelcoat on the hull where this cracking is. What is the best way of doing so?

There are specific tools to plane off the gelcoat, but cost over $800 at the low end. What am I looking at to do this, besides extremely hard work and many hours? Has anyone done this before at IBoat? I have seen it done on Betrams with the planer method as well as sandblasting, but I would prefer to sand if at all possible.

Thank you for taking the time to read, hopefully someone can point me in the right direction.

 

[tpenfield]

Re: Removing boat gelcoat - 1965 Boston Whaler 16'

You may not have to remove all of it, but substantially grind into it and also dig into the cracks with a sharp tool to open them up a bit.

Also, check for blisters, as the cracks may have appeared from repeated moisture absorption and then seasonal drying out. A barrier coat once you are all said and done with the gelcoat would be a good thing.

 

[Georgesalmon]

Re: Removing boat gelcoat - 1965 Boston Whaler 16'

There is no easy way. Grinding is the most common. I have used thise planers and they are hard work to. You just want to grind down to a good smooth, clean surface and get through the cracks if you can. Then use a good primer and fill whats left of the cracks and paint it. Putting on gelcpat and finishing the surface is a TON of work and needs a lot of wet sanding with big blocks and buffing to get it to look decent. Trust me painting is much easier and is still plenty of work. Lots of "how to's" on painting boats do some searching on here. JMHO

 

[Woodonglass]

Re: Removing boat gelcoat - 1965 Boston Whaler 16'

I would first try sanding with a R/O sander an 60 Grit paper. Depending on the thickness of the Gel you might be surprised with the results. If you go thru to the glass then GS's advice about the painting is sound. Gelcoating is kind of a challenge unless you have all the proper equipment and know how!

 

[fishingfrenzy]

Re: Removing boat gelcoat - 1965 Boston Whaler 16'

Thanks guys.

Right now the plan is to grind down the areas where cracks are grouped together, then glass with 1.5 CSM and 1708 until back to original thickness.

Sound okay?

Vinel Esther, is the route I want to go.

 

[tpenfield]

Re: Removing boat gelcoat - 1965 Boston Whaler 16'

Thanks guys.

Right now the plan is to grind down the areas where cracks are grouped together, then glass with 1.5 CSM and 1708 until back to original thickness.

Sound okay?

Vinel Esther, is the route I want to go.

Well, if you grind the gelcoat down just to the fiberglass . . . you may not need to build up the laminate as you indicated. So, it would be a matter of how good the fiberglass actually is once you get there. Keep in mind that if you remove too much material, it will be all that much harder to get back to a good original looking surface.