New Boat DIY: Sanding the Deck and Reapplying Gel Coat

New Boat DIY: Sanding the Deck and Reapplying Gel Coat

Congratulations on your new boat! Whether it’s your first vessel or you're venturing into a boat restoration project, redoing the deck is an exciting task. For first-time DIY boaters, sanding and reapplying gel coat might seem like a straightforward project, but it’s more labor-intensive than you might think. Here’s a breakdown of the steps and considerations to help you decide if two weekends will be enough time for the job.

1. Sanding the Deck: A Critical First Step

Sanding the deck is crucial before you can reapply the gel coat. You’ll want to remove any existing finish and smooth out any imperfections. It’s a time-consuming process that requires a lot of elbow grease, so it's important to approach it strategically.

• Make sure you have high-quality sandpaper—rough grit for the initial sanding and finer grit for smoothing the surface.
• Use electric orbital sanders (120mm or larger) for efficiency, but be prepared for some physical labor.
• Depending on the condition of the deck, you may need several hours of sanding just to get it down to the bare glass.

2. Filling Imperfections

Once the deck is sanded down to the glass, you’ll need to fill any imperfections before applying the new gel coat. This step is essential to ensure the surface is as smooth as possible for the gel coat application.

• Use a quality filler that is suitable for boats. Epoxy fillers work well for most repairs.
• Make sure to allow time for the filler to dry and sand it down to smooth out the surface.

3. Applying Gel Coat: The Labor-Intensive Part

Reapplying gel coat is much more labor-intensive than it seems. You’ll need to mix the gel coat and apply it evenly, and then allow it to cure before sanding it smooth.

• Be sure to follow the manufacturer’s instructions carefully, as improper application can lead to uneven surfaces.
• Multiple layers of gel coat may be necessary to get a smooth, professional finish.
• Don’t forget that sanding between each layer of gel coat is required to achieve the best results.

4. Sanding and Polishing

After the final coat has cured, you’ll need to sand and polish the surface to achieve a glossy, smooth finish. This final step is what will make your deck look like new.

• Start with a coarser grit for sanding and gradually move to finer grits.
• Once you’ve finished sanding, polish the surface to restore the glossy finish.

5. Is Two Weekends Enough Time?

While it may seem like a straightforward task, sanding and reapplying gel coat is a lengthy process, especially if you’re new to the job. Here's what you need to consider:

• With two people working on the boat, you can expect the project to take a considerable amount of time. The sanding and filling alone could take several hours, and that doesn’t include the gel coat application and curing time.
• Allow for at least 80 hours of work between the two of you, and even then, it might still take longer depending on the deck’s condition.

6. Conclusion: Plan Ahead

If you’re committed to completing the deck restoration in two weekends, it’s possible, but only with the right tools and a clear, focused plan. If you find that you’re running out of time or energy, don’t hesitate to extend the timeline for the project to ensure you get the best results. The effort is well worth it, and the satisfaction of completing this restoration yourself will make your boat feel even more like your own.