I have a fiberglass kayak (Cape Horn 17 Pro) about 15 years old made by wilderness systems. I bought it last year, seeing it has gel coat cracking all over the boat, but much worse on the left side on top of the deck. Lots of cracking in the paint and given it is significantly weaker than the opposite side, I’d say the fiberglass underneath is probably separating or no longer good. the repair area is going to be a little over a foot long. I think I have a good idea of what steps I need to take to repair it, however I wanted to see if someone could read over the steps I am going to take and correct me if any of them seem wrong. So here it goes.
I am planning to cut out the entire area with fiberglass separation, then I will be sanding down the edges to round them out. I will take making tape and run it over the hole on the outside of the boat. I will then be using whatever woven fiberglass cloth I can find and lay up 2 layers with epoxy fiberglass resin. I will remove tape and allow to cure, afterwards I will sand it down and apply gel coat over it.
The main part I am not sure on is how many layers of fiberglass cloth I should use, because this surface is also curved, I wasn’t sure if there was anything better than masking tape to get the curve correct, I wasn’t sure if I should possibly make a quick mold of the outside before cutting anything out. Also, say if only the outside fiberglass layers are cracked, could I potentially just sand down until Ive just got a thin inside fiberglass layer and just lay another cloth over it?
Thanks, any advise is greatly appreciated!