Repairing pitted or pin holed surfaces
Extensive corrosion or pinhole damage should be cut away with and replaced with new material by a repair professional. But as long as the damage is not too severe, you may reinforce the area with G/flex 650 epoxy and the following items not included in the kit:
• XK0400 400gm Fibreglass Fabric (0.762m x 0.762m)
• WEST SYSTEM 808 Flexible Rubber Squeegee
• WEST SYSTEM 803 Glue Brush (Metal handle brush)
• 80-grit sandpaper
These items will allow you to repair a damaged area up to 30.5cm x 30.5cm as follows:
1. Remove loose material with a wire brush and abrade the area with 80-grit sandpaper.
2. Treat the surface of damaged area with a two step aluminium etch - follow the manufacturer's instructions. (If a two-step etch is not available, abrade with 80-grit sandpaper immediately after applying a coat of G/flex 650 Epoxy. This removes the weak oxidation layer and exposes clean metal to improve adhesion.)
3. Dispense equal volumes of G/flex 650 Resin and Hardener into the mixing cup and stir thoroughly with the mixing stick. Then stir in enough 413 Microfibre Blend Powder to thicken the mixture to a "mayonnaise" consistency.
5. Cut a piece of XK0400 400gm fibreglass fabric slightly larger than the damaged area.
6. Dispense equal volumes of G/flex 650 Resin and Hardener into the mixing cup and stir thoroughly with the mixing stick.
7. Place the fabric on a piece of plastic. Using a disposable brush, apply the mixed epoxy to the fabric until it is saturated.
8. Position the wet fibreglass over the damaged area. Use a plastic spreader to smooth the fabric against the surface while wiping off excess epoxy.
9. When the fibreglass patch has cured to a duct tape-like tackiness, mix a batch of G/flex 650 and stir in enough 413 Microfibre Blend Powder to thicken the mixture to a "mayonnaise" consistency. Using a plastic spreader to apply this mixture over the patch and smooth out the edges of the fabric and blend the patch into the undamaged area around it.
10. Wipe the area with water and sand the epoxy smooth and dull before applying a final finish.
11. Apply a finish coating to protect the epoxy from the UV effects of sunlight. If the hull is painted, you can coat the repaired area with a marine primer and matching paint or an automotive primer and paint. Follow paint manufacturers recommendations.