Gel Coating After Painting: A Smart Move?

can you put gel coat on after new paint

Applying gel coat over paint is possible, but it is not recommended. While some sources suggest that gel coat can be applied over paint if the surface is properly cleaned, sanded, and primed first, others advise against it, stating that gel coat should not be applied directly over paint. It is important to note that paint is not as durable as gel coat and may require more prep work to achieve a desirable finish. On the other hand, gel coat is more forgiving and can be sanded down and started over if needed. Additionally, gel coat requires the addition of a fiberglass resin hardener or catalyst for proper curing, which adds to the complexity of the process.

Can you put gel coat on after new paint?

Characteristics Values
Durability Paint is less durable than gel coat
Prep work Paint requires more prep work than gel coat
Cost Gel coat is cheaper than high-dollar paint
Application Gel coat is more difficult to apply than paint
Appearance Paint may not have as high-quality a finish as gel coat
Repair Gel coat is better for repairing surfaces than paint

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Sanding and prepping the existing gel coat

Start by inspecting the surface for any imperfections, such as gouges, scratches, or blisters. Use heavier grits, such as 40/80/100 or 220/330, to sand and feather out these imperfections and the surrounding areas. This process will create a smooth transition and ensure that the repair blends seamlessly with the existing gel coat. Remember to work carefully and wear appropriate protective gear, including a respirator, to avoid inhaling any dust particles.

Once the repairs are complete, it's time to feather a 'flow' or sanding coat on the masked-off area. Make layered passes to avoid a buildup of gel coat in any one area. Each coat may involve several passes, so maintain even and consistent gun movement, slightly overlapping each previous pass. When spraying to a radius, flow the gel coat towards the tape, and in open flat areas, focus on layering passes. Aim for a final thickness of 18 ±2 mils minimum.

After you're done spraying, it's crucial to clean your sprayer with acetone immediately. Most gel coats will cure within 2-4 hours, but for optimal results, an overnight cure is recommended. Once the gel coat has cured, you can begin the wet sanding process. Use fine-grit sandpaper, typically starting with 320 or 400 grit, to remove any orange peel texture from the repaired area. This step will help you achieve a smooth surface while avoiding unnecessary sanding scratches.

Finally, progress to a finer grit, such as 600-grit sandpaper, to refine the surface further. After sanding, buff the area with a compound and wax to restore shine and achieve a "like new" look. Remember to work in a shady location or on an overcast day to avoid direct sunlight, as this can impact the curing process and the final appearance.

By following these steps and taking your time, you can ensure that the existing gel coat is properly sanded and prepped, creating an excellent base for your new gel coating application.

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Using a roller to apply paint

It is possible to paint over a gel coat, but it requires a lot of prep work. The surface must be properly cleaned, sanded, and primed before painting. Even after all this work, the paint may not be as durable as a gel coat.

If you are set on painting over a gel coat, using a roller to apply the paint is a good method. The key to success is to work quickly and apply thin coats of paint. Use a thin foam roller to apply a thin coat, then discard the roller before it starts to disintegrate. Use a new roller to lightly roll over the first coat to remove any bubbles. You can repeat this process to add additional coats of paint, without sanding between coats, as long as you follow the manufacturer's guidelines for recoating.

If you are applying a gel coat with a roller, you will need to work quickly as the gel coat will start to cure fast. It is recommended to use a medium roller for this job, as a very fuzzy roller will not work well with the thick consistency of the gel coat. You will also need a brush to help move the gel around and to tip off any excess. Apply a quick wet coat, followed immediately by a finish coat. Make sure to remove any tape before the gel starts to cure.

For both painting and applying a gel coat, it is important to have a plan and stick to it to avoid painting yourself into a corner.

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Spraying gel coat

Preparation

Firstly, decide on the equipment you will use. You can use brushes for smaller crafts or areas, but for a larger craft like a boat hull, a spray gun is recommended. You can purchase a suitable spray gun for around $130, and you may also need to invest in an air compressor. If you are using a pressure pot system, you will need a large fluid nozzle (above 1.8) and a pressure pot outfit, which can be purchased together for around $954.

Mixing the Gel Coat

Gel coat should be prepared in 5 oz batches to ensure a longer pot life. You will have approximately 15-20 minutes to apply the first coat. Before adding a thinner, consider adding a sanding aid like FGCI Wax Additive, which helps cure the resin at room temperature and creates a less tacky surface for sanding. Only add thinner when using a gravity-fed spray gun. For a "Cup" gun, you can add the gel coat thicker, but this may result in a less smooth finish. There are two types of thinners: reactive thinners, which mix with the gel coat, and evaporative thinners, which dissipate within the resin, leaving mostly pure gel coat.

Spraying Technique

Before spraying, ensure your mold is clean, free from defects, and treated with a proper mold release agent. It is also crucial to atomize the gel coat well to prevent air from getting trapped, which can cause blistering. Remove all water vapor from your compressed air supply to avoid introducing moisture into the gel coat during spraying. Alter the catalyst ratio if necessary, depending on the temperature—add more catalyst if it is cold (below 70 degrees Fahrenheit) and reduce it if it is too hot to ensure proper curing.

Aftercare

Once the gel coat is applied, check carefully for bubbles and blisters, and treat them immediately. These are weak points that can allow water absorption into your fiberglass hull. Maintain the shiny appearance of your hull with boat soap, marine boat polish, and chamois cleaning cloths for scratch-free and lint-free washing.

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Using a brush to apply gel coat

Applying gel coat with a brush is a common method, but it has its disadvantages. When using a brush, the gel coat cannot be applied in a perfect "self-leveling" coat. It must be mechanically finished by wet/dry sanding and polishing for a "like new" look.

To get started, you'll need to sand the entire surface to be coated with 150-grit sandpaper. If there are cracks or gouges, repair them first. The surface should be free of flaws and perfectly smooth before applying the gel coat. It is recommended to use a natural bristle brush with tapered ends. Choose a shady location or an overcast day, and avoid direct sunlight. You should catalyze your material so that it cures as quickly as possible within your working time. Generally, mix one-pint batches, and pour the mixed gel coat from the mixing container into another container used for application. This ensures that no uncatalyzed material is clinging to the sides of the pot.

When applying the gel coat, "lay on" the gel coat in a heavy thickness (about 10 mils) using horizontal strokes, and work from top to bottom. Avoid re-brushing as this could remove the wax additive that will rise to the top. Remember to always lap wet. Generally, one heavy coat is sufficient. However, if you have opacity problems, two coats may be necessary with light sanding between coats.

After the gel coat has cured, it should be block-sanded using a 250-wet grit paper to remove all brush marks and high spots. Then, it should be wet sanded with 320, 400, and 600 wet grit paper, buffed, polished, and waxed.

It is important to note that brushing gel coat requires more prep time and application time compared to spraying. Brushing may be more efficient for small patches such as chips, dings, scratches, and minor repairs. For larger areas, spraying is usually a better option.

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Repairing cracks and gouges

When repairing cracks and gouges, it is important to first assess the extent of the damage. Small cracks, scratches, and chips in the gel coat can often be repaired with a gel coat repair kit, which typically includes everything needed for colour matching and filling in minor imperfections. Before beginning any repairs, the area must be cleaned with soap and water and dried thoroughly. If the surface is oxidized, use a rubbing compound to restore it and ensure an accurate colour match.

Once the surface is prepared, use masking tape to mark off the repair area. For small, narrow cracks, it is necessary to gouge them out until they are wide enough to fill with gel coat paste. A miniature grinding tool like a Dremel or even the sharp point of a can opener can be used for this step. Be sure to open up the crack sufficiently to expose enough surface area for the repair to adhere properly. After gouging out the crack, lightly sand the area with 220-grit sandpaper.

The next step is to clean the sanded area with acetone, ensuring proper ventilation and protection for your skin and eyes during this process. Then, it is time to mix the gel coat paste. Start with a white or neutral gel coat paste (not resin) and add small amounts of a colouring agent to match the existing gel coat colour. Mix several test batches of gel coat and pigment, adding hardener, and allow them to cure. The gel coat will change colour during curing, so this step is crucial for achieving an accurate colour match.

Once you have achieved the desired colour match, use a putty knife to fill the repair area with the mixed gel coat paste. Be sure to force out any air holes and overfill the area, as gel coat tends to shrink as it cures. Seal the repair from the air using a PVA curing agent or plastic wrap. After the gel coat has fully cured, sand the repair smooth, starting with 220-grit sandpaper and progressing to 400- or 600-grit for a slick finish.

It is important to note that cracks appearing at stress points, such as corners, or important joints and intersections, may indicate underlying structural weaknesses. If cracks radiate from the base of load-bearing equipment, there could be an installation problem that needs to be addressed before repairing the gel coat. In such cases, it is advisable to consult a marine surveyor or qualified boat maintenance worker to ensure that the issue is not serious.

Frequently asked questions

No, gel coat should not be applied directly over paint. However, you can paint over gel coat if the surface is properly cleaned, sanded, and primed.

Before applying gel coat, it is important to remove all grease, oil, wax, or any other foreign material. All surfaces must be sanded and cleaned.

Gel coat can be applied by spraying or brushing. Spraying is the preferred method as it results in a smoother and more even finish. Brushing may require additional finishing steps such as wet/dry sanding and polishing to achieve a "like new" look.

Gel coat is more durable than paint and is forgiving if you make a mistake during application. Gel coat can be sanded down and redone if necessary. It is also cheaper than high-dollar paint.

Yes, you may consider using a primer/sealer combination or a top coat such as Alexseal 442 primer and Alexseal top coat. LPU finishes are also an option, which can provide a better appearance and protection for your boat.

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