Category Archives: Epoxy

When to use Gelcoat vs Epoxy for Boat Repairs and Maintenance

Maintaining a boat involves more than just keeping it clean and stocked with gear—it’s about protecting your investment from the harsh marine environment. Two of the most common materials used in boat repair and maintenance are gelcoat and epoxy resin. While both serve vital roles in fiberglass boat construction and restoration, they are not interchangeable.

In this guide, we’ll break down the differences between gelcoat and epoxy, explain when to use each, and help you make informed decisions that will keep your boat seaworthy and looking sharp.

Let’s start with an understanding of the basics

What is Gelcoat?

Gelcoat is a pigmented polyester or vinyl ester resin used as the outer layer of most fiberglass boats. It provides a smooth, glossy finish and helps protect the underlying fiberglass laminate from UV rays, water, and minor abrasions.

Primary Purpose: Aesthetic finish and surface protection
Application: Typically applied in a mold during boat construction or used later for cosmetic repairs

Our products are formulated to provide superior resistance to UV rays and meet the stringent requirements of the boating industry.

What is Epoxy?

Epoxy resin is a two-part adhesive consisting of a resin and a hardener. When mixed, it forms a strong, durable material ideal for structural repairs and bonding various surfaces, including fiberglass, wood, and metal.

Primary Purpose: Structural repairs, strong bonding, waterproofing
Application: Used in layups, laminating, filling, or as a base layer for barrier coats

Tuff Stuff is designed as a high-build two-part epoxy primer, making it ideal for barrier coats, especially below the waterline. It’s specifically engineered to prevent water absorption and osmotic blistering in fiberglass hulls—a core strength of marine-grade epoxies.

Gelcoat vs. Epoxy: Key Differences

Feature	Gelcoat	Epoxy Resin
Primary Use	Surface finish, color, UV protection	Structural repairs, bonding, sealing
Strength	Less strong, brittle under stress	Extremely strong, flexible under stress
UV Resistance	Excellent	Poor – requires UV-resistant topcoat
Water Resistance	Good	Excellent
Adhesion	Best on cured polyester/fiberglass	Bonds to wood, metal, fiberglass, epoxy
Ease of Use	Faster to apply, but less forgiving	Longer cure time, requires precision

When to Use Gelcoat

Gelcoat is your best choice when the goal is cosmetic restoration of your boat’s surface—particularly fiberglass. It’s ideal for:

Repairing surface scratches and chips in the existing gelcoat
Restoring faded or oxidized areas
Matching the boat’s original finish and color
Protecting from UV damage and surface wear

However, gelcoat does not bond well to epoxy or non-polyester surfaces unless properly prepped. Also, it’s not suitable for deep repairs or structural issues.

Best Time to Use Gelcoat:

Restoring surface shine on fiberglass
Filling shallow scratches, dings, and UV damage
Matching original boat color (especially white, because, well… everything’s white)
Cosmetic touch-ups above and below the waterline

Tip: Always sand and clean the surface thoroughly before applying gelcoat. If applying over epoxy, ensure the epoxy is fully cured and properly sanded to create a mechanical bond.

When to Use Epoxy

Epoxy is the material of choice when strength, durability, and waterproofing are the priorities. It excels in situations like:

Repairing delaminated fiberglass
Fixing holes, cracks, or structural damage
Bonding dissimilar materials like wood to fiberglass or metal
Sealing bare fiberglass or wood to prevent water intrusion
Creating a barrier coat to prevent blistering (osmosis)

Epoxy is more chemically resistant than polyester resins and has superior adhesive qualities. However, it requires a UV-resistant topcoat, such as topside boat paint or gelcoat, to protect it from sunlight degradation.

Best Time to Use Epoxy:

Repairing structural damage like cracks, holes, or delamination
Sealing bare fiberglass to prevent water intrusion
Adhering materials (wood, metal, composite) with confidence
Filling deep gouges or rebuilding missing chunks
Barrier coats to prevent osmotic blistering

Can You Use Gelcoat Over Epoxy?

Yes, but with preparation. Since gelcoat does not naturally adhere well to epoxy, the epoxy must be fully cured, sanded with 80–120 grit, and cleaned thoroughly to allow for mechanical bonding. Some professionals recommend applying a tie-coat primer to improve adhesion.

Choosing the Right Product

Use Gelcoat when:
You’re doing surface-level cosmetic work on fiberglass and want a UV-resistant, glossy finish.
Use Epoxy when:
You’re repairing structural damage, bonding materials, or sealing surfaces below the waterline.

Final Thoughts

Whether you’re restoring your hull’s shine or reinforcing a damaged section, knowing when to use gelcoat vs epoxy ensures your boat stays safe, seaworthy, and beautiful. Each material serves a distinct purpose—gelcoat for finishing and appearance, epoxy for strength and structural integrity.

By understanding their properties and correct applications, you’ll be able to tackle any repair with confidence—and save time and money in the long run.

Ready to tackle your next boat project like a pro?

Stock up on top-rated gelcoat and epoxy products at Bottom Paint Store and cruise into your next DIY with confidence. Need help? We are only a phone call 888-505-2313 or live chat away.

How to select marine paint

Ahoy there, fellow seafarers! Are you ready to sail the high seas with style and pizzazz? Selecting the right marine paint is critical to the appearance, longevity, and performance of a boat. Marine paint not only adds an aesthetic appeal to the boat but also protects the hull from environmental elements such as water, sunlight, and salt. It can also help reduce the drag and improve fuel efficiency of the boat.

When choosing marine paint, there are several factors to consider such as the type of paint, the water conditions in which the boat will be used, the type of hull material, the application method, and the expected maintenance. These factors can affect the durability and effectiveness of the paint, as well as the overall appearance of the boat. So, don’t be like a sailor who forgot to batten down the hatches – take the time to select the right boat paint. Your boat (and your reputation as a savvy boater) will thank you.

KEY TAKEAWAYS

Choosing the right marine paint is important for both the appearance and protection of your vessel.

There are different types of marine paints, such as antifouling paint, topside paint, and bottom paint, each with its own purpose and application.

When selecting marine paint, it’s important to consider factors such as water conditions, hull material, and application method.

Proper application of marine paint is crucial for achieving a smooth, even finish and ensuring the paint lasts as long as possible.

Maintaining your boat paint with regular cleaning and touch-ups can help preserve the value of your vessel and keep it looking great.

Types of marine paints

There are several types of marine paints available in the market, each designed for a specific purpose. Here are some of the most common types of boat paints:

Antifouling paint – Antifouling paint is designed to protect the hull of the boat from the growth of marine organisms, such as algae and barnacles. It contains biocides that inhibit the growth of these organisms, preventing them from attaching to the hull. Antifouling paint is best used in saltwater or brackish water environments.

Topside paint – Topside paint is used to protect the upper part of the boat above the waterline. It can be used on the deck, cabin, and other areas exposed to sunlight and harsh weather conditions. Topside paint comes in a variety of finishes, from matte to glossy, and can be customized to match the desired look of the boat.

Bottom paint – Bottom paint is designed to protect the hull of the boat below the waterline. It prevents the growth of marine organisms, such as barnacles and mussels, which can cause drag and reduce the boat’s performance. Bottom paint is best used in saltwater or freshwater environments.

Epoxy paint – Epoxy paint is a two-part paint system that is highly durable and resistant to water, chemicals, and abrasion. It is commonly used as a primer or barrier coat to protect the hull from moisture and corrosion. Epoxy paint can also be used as a topcoat for added protection and a glossy finish.

Varnish – Varnish is a clear, protective coating used to enhance the natural beauty of wood on the boat. It provides UV protection, moisture resistance, and durability to the wood, making it last longer and maintain its appearance.

The type of marine paint to use depends on the intended use of the boat and the environmental conditions in which it will be used. For example, antifouling paint* is best used in saltwater environments to prevent marine growth, while topside paint can be used to enhance the boat’s appearance and protect it from UV rays. Bottom paint is ideal for boats that spend a lot of time in the water, while varnish is suitable for boats with wooden surfaces that need protection and a glossy finish.

Factors to consider when selecting marine paint

When selecting the right marine paint, there are several factors that should be taken into account. Here are some of the most important factors to consider:

Water conditions – The type of water in which the boat will be used is a critical factor to consider when choosing boat paint. Saltwater, freshwater, and brackish water each have different environmental conditions that can affect the performance and durability of the paint. Saltwater, for example, can be corrosive and requires a more durable paint that can withstand the harsh environment.

Hull material – The material of the boat’s hull is another important factor to consider when selecting boat paint. Different types of paint are designed to adhere to specific materials, such as fiberglass, aluminum, or wood. It’s important to choose a paint that is compatible with the hull material to ensure proper adhesion and maximum protection.

Application method – The application method of the paint can also affect the final appearance and performance of the paint. Some types of paint, such as epoxy paint, require a specific application method, while others, such as topside paint, can be applied using a brush, roller, or spray. It’s important to choose a paint that can be applied using the desired method and to follow the manufacturer’s instructions for the best results.

Expected maintenance – The expected maintenance of the boat paint is another factor to consider when selecting boat paint. Some types of paint, such as antifouling paint**, require more frequent maintenance, such as cleaning and touch-ups, to maintain their effectiveness. It’s important to choose a paint that fits your maintenance schedule and skill level.

Tips for evaluating these factors and making an informed decision

Consult with a professional or a trusted boat maintenance expert, such as Bottom Paint Store, to help you evaluate the different factors and choose the right boat paint for your needs. offers free technical assistance.

Research different brands and types of marine paint to compare their performance, durability, and cost-effectiveness.

Check the manufacturer’s recommendations and application instructions to ensure compatibility with your boat’s hull material and the intended application method.

Consider the expected lifespan of the paint and the frequency of maintenance required to ensure the paint remains effective.

Finally, remember that selecting the right marine paint is an investment in the long-term performance and appearance of your boat, so take the time to make an informed decision.

Applying marine paint

Properly applying marine paint is crucial to achieving a smooth, durable finish that protects your boat from the harsh marine environment. Here’s why it’s important and how to do it:

A proper application ensures the paint adheres to the surface and forms a protective barrier against the elements.

Applying paint unevenly or too thinly can result in a weak bond that can crack, peel, or fade prematurely.

Proper application also ensures the paint dries evenly and maintains its color and gloss for longer.

Step-by-step instructions for applying marine paint

Surface Preparation: Before applying any paint, clean the surface thoroughly to remove any dirt, grease, or other contaminants. Sand the surface to create a rough texture that promotes adhesion.

Primer: Apply a primer to the surface to promote adhesion and provide a smooth base for the paint. Allow the primer to dry completely before applying the paint.

Application: Apply the paint using a brush, roller, or spray gun, depending on the type of paint and the desired finish. Apply the paint in thin, even coats, and avoid overloading the brush or roller.

Drying: Allow each coat to dry completely before applying the next coat. Follow the manufacturer’s instructions for the recommended drying time between coats.

Sanding: Sand the surface lightly between coats to create a smooth texture and promote adhesion.

Final Coat: Apply the final coat of paint using the same technique as the previous coats. Allow the final coat to dry completely before using the boat.

Tips for achieving a smooth, even finish:

Use high-quality paint and tools to achieve a professional-looking finish.

Apply the paint in thin, even coats to prevent runs and drips.

Avoid painting in direct sunlight or high humidity to prevent the paint from drying too quickly or not drying properly.

Follow the manufacturer’s instructions for the recommended number of coats and drying time between coats.

Sand the surface lightly between coats to create a smooth texture and promote adhesion.

Use a high-quality brush or roller to ensure the paint goes on evenly.

Keep the paint mixed well to maintain consistency throughout the application process.

Maintaining marine paint

Properly applying marine paint is crucial to achieving a smooth, durable finish that protects your boat from the harsh marine environment. A proper application ensures the paint adheres to the surface and forms a protective barrier against the elements. Applying paint unevenly or too thinly can result in a weak bond that can crack, peel, or fade prematurely. It also ensures the paint dries evenly and maintains its color and gloss for longer.

Where to buy marine paint

In summary, choosing the right marine paint is essential for protecting your vessel from the harsh marine environment and ensuring it looks its best. Factors like water conditions, hull material, and application method should all be taken into account when selecting the right paint for your boat. Once you’ve chosen the right paint, be sure to apply it properly to achieve a smooth, even finish. And remember, a well-maintained paint job not only looks great but can also help preserve the value of your boat.

So, don’t be like a bad paint job – sloppy, uneven, and ultimately disappointing. Take the time to select the right paint and apply it properly. Your boat (and your wallet) will thank you. Bottom Paint Store has a huge selection of marine paint at discounted prices and if you need technical assistance, feel free to contact us Monday to Friday 9am-5pm EST 888.505.2313.

Source:

*Wikipedia Anti-fouling paint

** Marine fouling and its prevention ; prepared for Bureau of Ships, Navy Dept.

The different uses for Hawk Epoxy

If you’re a boat owner, there’s a good chance you’re familiar with Hawk Epoxy by SeaHawk Paints; however, did you know there are several diverse ways to use it? In this post, we’ll take a look at some of the different ways Seahawk Hawk Epoxy can be used to keep your boat in top condition. So, whether you’re a beginner or an experienced boater, read on for some helpful tips!

What is epoxy?

Epoxy is a type of adhesive that is commonly used to bond two surfaces together. It is made up of a resin and a hardener, which are mixed together to form a tough, durable bond.

Unlike other sealants, epoxy is able to form a strong bond with the surface it is applied to, making it an ideal choice for sealing concrete, metal, and glass. Epoxy is also resistant to temperature changes and UV light, making it ideal for use in outdoor applications. In addition to its practical benefits, epoxy can also be used to create interesting visual effects. When applied to a surface in thin layers, epoxy can create a marbled or even tie-dye effect. As a result, epoxy is a versatile material that can be used for both functional and decorative purposes.Epoxy is typically used for repairing metal, plastic, and glass.

It can also be used for bonding wood, concrete, and ceramic. Epoxy is available in both liquid and powder form. The liquids are typically used for small repairs, while the powders are better suited for larger projects. Epoxy is typically applied with a brush or roller. Once it has been applied, it needs to be allowed to cure for 24 hours before it can be used.

Hawk Epoxy can be used as a sealant to protect surfaces from water and other elements.

Fairing Hull Imperfections with Hawk Epoxy

Let’s face it, our boats take a beating. They’re exposed to the sun, the salt, the waves, and the wind on a daily basis. So, it’s no wonder that even the best-kept boats can start to show their age after a few years. One of the most common problems is fairing hull imperfections. These are small cracks or indents in the gelcoat that can make your boat look old and worn. But don’t despair, there is a simple way to fix this problem with hawk epoxy.
Hawk epoxy is a two-part epoxy resin that you mix together to create a putty-like substance. Once it’s mixed, you can use it to fill in any cracks or indentations in your hull. It dries hard and sets fast, so you can sand and paint over it once it’s dry. And best of all, it’s very affordable. So, if your boat is starting to look a little worse for wear, don’t worry, just grab some hawk epoxy, and give your boat a facelift.

Patching Holes in a Boat with Hawk Epoxy

There’s nothing worse than getting your boat out on the water only to find that it’s taking on water. Fortunately, patching holes in a boat is relatively easy to do, as long as you have the right materials.

Hardware Replacement Adhesion with Hawk Epoxy

Hawk epoxy’s two-part epoxy provides a strong, permanent bond and can be used on a variety of materials, including metal, glass, ceramic, and plastic. And it sets in just minutes, so you won’t have to wait around for hours for it to dry. Plus, it’s easy to use – just mix the two parts together and apply it to the surfaces you want to bond.

Hawk Epoxy Proper Measuring and Mixing

Anyone who has ever worked with epoxy knows that it is crucial to get the measuring and mixing process exactly right. Too much or too little of either ingredient can ruin the entire batch, and that can be a costly mistake. Hawk Epoxy strives to make the measuring and mixing process as simple and foolproof as possible. Our epoxy products come with clear instructions and easy-to-use tools that make it easy to get the perfect mix every time. If you follow the provided instructions, you can be confident that your epoxy project will turn out just the way you want it to.

Applying Hawk Epoxy

Hawk epoxy is specifically designed for use on boats, and it’s perfect for patching small holes. The epoxy comes in two parts that you mix together, and then it can be applied directly to the hole.
Sometimes, you need something more than just epoxy resin. That’s where Hawk epoxy fiberglass cloth and mat come in. The cloth and mat help to reinforcing the epoxy, making it stronger and more durable. They can be used to repair cracks, leaks, or holes in a variety of surfaces, including concrete, metal, glass, and wood. Best of all, the cloth and mat are easy to apply and can be cut to fit any size or shape. So, whether you’re patching up a small crack or fixing a large hole, Hawk epoxy fiberglass cloth and mat can help you get the job done right.
First, clean the area around the hole with sandpaper to make sure that the epoxy will adhere properly. Then, mix the epoxy according to the instructions and apply it to the hole. Once it dries, the epoxy forms a strong bond that will keep the hole sealed. It is important to note that the curing time may vary depending on your temperature and humidity levels.
Once properly applied and cured your boat will be good as new – no leaks guaranteed!

Sealing a Fiberglass Hull with Hawk Epoxy

Sealing a fiberglass hull with epoxy is a great way to extend the life of your boat. Epoxy is a strong, durable material that will create a waterproof barrier between the hull and the water. It is important to properly prepare the surface before applying the epoxy, and to follow the manufacturer’s directions closely. Once the epoxy has been applied, it is important to allow it to cure properly before using the boat. With proper preparation and care, sealing a hull with epoxy will help to keep your boat in good condition for many years to come.

How to apply Hawk Epoxy

Epoxy is a type of synthetic resin that is often used as an adhesive or coating. It is typically made up of two parts that are mixed together and then cured to form a hard, durable finish. Hawk Epoxy by SeaHawk paints is a two-part epoxy that can be used for a variety of applications, including bonding, coating, and laminating. Before using Hawk Epoxy, it is important to read the instructions carefully and to follow all safety precautions. Once you have mixed the two parts of the epoxy together, you will have a limited time to apply it before it begins to set. For best results, apply the epoxy to a clean, dry surface and use a brush or roller to spread it evenly. Once it has been applied, the epoxy will need to cure for 24 hours before it is fully cured. However,

Hawk Epoxy is a versatile product that can be used in many different ways. We’ve highlighted just a few of the potential applications for this amazing adhesive. If you have questions for how to use Hawk Epoxy or need help bringing your boat painting project to life, contact the Bottom Paint Store customer service team Monday through Friday 9-5 EST 888-505-2313.

Filler Options for Gelcoats and Resins

There are many common fillers used with gelcoat and resin and here we’ll help you pick the one that is right for you.

When using putty, a good rule is not to go higher than 1/8″ thick without adding a layer of glass to prevent any issues. With the various fillers, for the right working consistency, you’ll want about 60-70% mix to resin ratio.

Milled Fibers: Finer than chopped glass, makes a harder putty that is strong and coarse.

Walnut Shells: Brown in color and preferred for wood putty or nonskid since it has large particles. Good Strength and darker pigment.

Microballoons or Microspheres: Phenolic spheres are generally plastic or glass and hollow, intact spheres that are lightweight. This is ideal for making fairing compounds. The Microballoons are a more expensive option for filler.

Fumed Silica: Also known as Cabosil FIller or Aerosil Filler. This is a hydrophilic fumed silica. Fumed Silica provides little change to weight, color, or physical properties after cure, used in resins and gelcoats to make them hang on vertical surfaces, (too much can cause porosity.)

Cotton Flock: Made from pieces of cotton and thickens to an off-white color. Great for bonding many substrates, especially wood. The mixture also creates a multipurpose adhesive for many other substrates in addition to providing excellent substrate wetting and penetrating characteristics. Increases impact and abrasion resistance.

Chopped Glass: These are the biggest pieces of fillers and are most popular for use with resin putty. Perfect for corners, crack resistant, and doesn’t affect pigmented gelcoat. 1/4″ glass fibers make the strongest glass reinforced putty.

How to repair a hole on the side of your boat

Repairing a hole on the side of your boat is possible by following this guide and using epoxy resins for wooden boats.

Begin by inspecting the hole for any cracks that extend away from the
hole and clearly mark the entire area that needs to be patched. You want to be sure to extend your mark out beyond the damaged area by a few inches.

Hawk Epoxy f2 Structural Adhesive Filler

Cut the marked area with a hand saw making sure the hole is beveled in order to allow layers of fiberglass to fill the hole. Measure the thickness of the hull substrate and multiply it by 10. This is the distance from the hole edges that the bevel needs to accommodate.

Use a power sander with a 50 grit sanding disc to bevel from the whole edge out to your mark. Fiberglass layers are going to be placed on the outside of the hull. Use a flat backing on the inside of the hole to keep the wet fiberglass cloth from caving into the hole.

Next cut six pieces of fiberglass bi-axle cloth with the first piece being the size and shape of the outer edge of the bevel. The final sixth piece being the size of the hole itself. Remember it is important to use fiberglass bi-axle cloth for hole repairs.

Wet out the beveled area of the hole with a mixed epoxy. Lay the cut fiberglass bi-axle cloth on a piece of plastic going from large to small pieces. Make sure to wet each piece as you place them on top of the next piece. When wetted out properly the bi-axle cloth will become transparent. Put the wet out pile of fiberglass bi-axle cloth into a piece of peel ply, with the small pieces down. Next, mix the Hawk epoxy f2 filler and hawk epoxy resin catalyst until you reach a soft butter consistency.

Brush this mixture onto the beveled area of the hull and be sure to center your filler. Wipe off any extra leftover epoxy from the hull, squeegeeing out the air pockets and wiping with a clean cloth that has been dampened with solvent. This will be a lot easier than sanding it off later. Allow the patch to cure for the recommended cure time (overnight is typically sufficient) per the instructions on the hawk epoxy resin can label.

Once it has cured, remove the repair area backing on the inside of the hull. The repair area on the inside of the hull can be left untreated if it will not be exposed to sunlight. Remove blush with soap and water. Next sand off any rough areas on the outside of the hull with 80 grit sandpaper and then sand with 100 grit sandpaper the entire repair area so it is completely smooth (this may require a disc sander if it’s too difficult to sand by hand). You can dust off the area a clean cloth, air gun or brush it off with a clean brush.

Prepare a batch of Hawk epoxy resin and catalyst. Apply coats to the repair area with wet epoxy, with the remainder of the Hawk epoxy resin mixed in the Hawk epoxy f5. Lightly mix filler until density is a medium thickness
with no sag consistency.

Next, spread the mixture onto the repair area and squeegee the area until as smooth as possible. Allow the area to cure until you can push the corner of the squeegee into the surface and only a slight indentation remains. Repeat the process with Hawk epoxy mixed resin and f5 light density filler, adding another coat of this mixture onto the repair area. Let this cure for 10 to 12 hours.

Remove the blush with soap and water and sand the repair area with a smooth 80 grit sandpaper.

To add color, mix another small batch of Hawk epoxy and introduce the liquid dispersion as this will seal and fill any low areas. Now that you have a strong and
sturdy hull side you are ready for paint!

How To Patch a Hole in a Fiberglass Boat

A fiberglass boat is a great investment. They are durable and can last for years with proper care. But like anything else, they are not indestructible and will eventually need to be repaired. One of the most common repairs is patching a hole in the hull. Fortunately, this is a relatively easy repair that can be done by anyone with basic fiberglass repair skills.

The first step is to clean the area around the hole. This will remove any dirt or debris that could prevent the patch from adhering properly. Next, cut a piece of fiberglass cloth that is slightly larger than the hole. Apply a generous amount of fiberglass resin to the cloth and then place it over the hole. Use a roller or brush to smooth out the cloth and remove any air bubbles. Allow the resin to cure for 24 hours before sanding down the area and painting over it. With a little time and effort, you can have your fiberglass boat looking like new again.

A major fiberglass repair, such as patching a hole, can be a daunting task. Watching a professional do the job can help you get on the right track and be confident in doing the repair yourself. This step-by-step video tutorial produced by Sea Hawk Paints will show exactly what needs to be done when patching a hole in your fiberglass boat.

Note: Before attempting a repair by yourself, get a professional opinion. Always wears Personal Protective Equipment when sanding or working with chemical compounds! Respirator, safety glasses and gloves are always recommended.

Here is a list of products you will need for the repair:

Hawk Epoxy Resin Kit – It contains the epoxy resin, catalyst and filler for the job.
F5 Light Density Filler
Biaxial Fiberglass matting
50 grit, 80 grit, and 100 grit sandpaper or grinding pads

Hawk Epoxy Video Tutorial

For more information see these other How To Articles:

Filling a Hole in Fiberglass

How Do I Choose Hawk Epoxy Catalyst and Fillers?

How to Mix Hawk Epoxy Resin Properly

Fairing Hull Imperfections

How to Get Strong Hardware Adhesion with Hawk Epoxy

epoxy repair kit What is the best way to achieve maximum adhesion when replacing your boat’s hardware? This How To article will give you the basic knowledge you need to get your repair done correctly.

Note: Before attempting a repair by yourself, get a professional opinion. Always wears Personal Protective Equipment when sanding or working with chemical compounds!

Here are some simple steps to follow when bonding hardware to your boat:

Sand both the surface and the hardware to get maximum adhesion.
Wet out the surface with Hawk Epoxy.
Wait a few minutes for it to soak in.
Wet out the Hardware base with Hawk Epoxy.
Mix another batch of Hawk Epoxy with F2 Structural Adhesive Filler.
Coat the hardware base, screw threads, and surface mount with the epoxy/filler compound.
Tighten hardware bolts until some epoxy mixture squeezes out.
Use your finger to fillet the excess mixture around the hardware base for extra strength.
Before using the hardware, allow the bond to cure overnight.

Hawk Epoxy Video Tutorial

For more information see these other How To Articles:

How Do I Choose Hawk Epoxy Catalyst and Fillers?

How to Mix Hawk Epoxy Resin Properly

Filling a Hole in Fiberglass

Fairing Hull Imperfections

What is Fairing?

Fairing is process of smoothing out and restoring the damaged surface of the hull. A fairing compound such as Epoxy resin can be used to fill in divots or gouges and then be sanded to a smooth finish. This restores the surface to its original shape and also prepares it for painting.

Note: Before attempting a repair by yourself, get a professional opinion. Always wears Personal Protective Equipment when sanding or working with chemical compounds!

Here are some guidelines to fairing out imperfections in your hull:

Sand all loose surface debris and hard edges.
Rid surface of debris with clean cloth.
Wet out surface with Hawk Epoxy.
Mix another batch of Hawk Epoxy with F5 Light Density Filler and apply to repair area.
Use long strokes to spread out filler compound over the damaged hull. Apply until the mixture is slightly raised above the hull surface. Make sure the compound extends beyond the repair area.
Let cure 6 hours.
Add skim coat of F5 Filler / Epoxy compound to achieve a very smooth surface. Let cure.
Sand the repair to the desired shape with 80 grit sandpaper.
Finish by applying another 2 or 3 layers of Hawk Epoxy Resin.
The surface is ready to be painted!

Hawk Epoxy Video Tutorial

For more information see these other How To Articles:

How Do I Choose Hawk Epoxy Catalyst and Fillers?

How to Mix Hawk Epoxy Resin Properly

Filling a Hole in Fiberglass

How to Get Strong Hardware Adhesion with Hawk Epoxy

How to Mix Hawk Epoxy Resin Properly

Sea Hawk’s Epoxy Pump Kit makes it easier than ever to measure the Resin to Catalyst ratio very accurately, and get the same result every single time! But how are the pumps intended to be used?

hawk-epoxy-pump-kit-large-152x154 The Pump Kits come in two sizes, one kit accommodating the Size 1 and 2 Resin and Catalysts, and one kit accommodating the Size 3 Resin and Catalysts. Be sure to get the right size kit for the amount of resin and catalyst you plan on using. The Kit contains a total of 3 pumps; one for R1 Resin, one for C2 & C3 Catalyst, and one for C1 & C5 Catalyst.

The Hawk Pump Kit User Manual and instructional video explain how to use the pumps for accurate measuring, how to prime the pumps, pump cleaning and storage, and how to use the pumps with various Hawk Epoxy System Sizes.

Click here for Hawk Epoxy Size 1 and 2 User Manual

Click here for Hawk Epoxy Size 3 User Manual

Hawk Epoxy Video Tutorial

Can Aluma Hawk Paint be used with Tuff Stuff Epoxy Primer?

https://www.bottompaintstore.com/topside-boat-paint-aluminum-boat-paint-c-13630_14141.htmlThe direct answer is Yes.

Sea Hawk Tuff Stuff Epoxy Primer is an effective water barrier and universal primer. When applied to metal hulled boats it can serve as corrosion protection below the waterline. Therefore many boaters want to have that sort of protection on their Jon boat and apply Aluma Hawk Boat Paint on top. Aluma Hawk is an aluminum boat paint that is one of the easiest and most popular paints for aluminum boats. It is a quick-dry, high-solids, corrosion-inhibiting coating designed for use on https://www.bottompaintstore.com/blog/aluminum-application/can-tuff-stuff-epoxy-primer-be-used-with-aluma-hawk-paint/an aluminum surface without the need for additional primers. It is chromate-free and may be used above or below the waterline in fresh or saltwater environments. You can paint Aluma Hawk with a brush, roller, or spray. Apply 2 coats following the proper dry time requirements. No sanding is necessary between coats of Aluma Hawk if less than 48 hours between coats. Thinning: thin if necessary with MEK.

When over-coating Tuff Stuff Epoxy Primer it is important to meet the required over-coating times in order to achieve the best adhesion because temperature and humidity have a direct impact on dry times. QUICK and EASY RULE: When the coating is dry to the touch, yet still has some tack, it is ready to be over-coated. Your thumb will leave a print without lifting any epoxy. This is called hot-coating. However, if the coating is completely cured (or after 24 hours) it needs to be thoroughly sanded with 80 grit sandpaper to remove the shine, or you must apply another coat of Tuff Stuff within 6 days. Then you have an additional 24-hour maximum window to overcoat with paint.

These two products are great on their own, but they can do so much more when working in conjunction with each other.

Filling a Hole in Fiberglass

When you are trying to repair a small hole in fiberglass, the best type of product to use is a premium epoxy. This will insure a proper repair and will not allow for shrinking of the material and create a water tight seal.

We recommend the Hawk Epoxy Kit. It contains the epoxy resin, catalyst and filler for the job. Watch the video below to see the steps needed to perform a small hole repair.

How to sand fiberglass for paint

Whether you’re trying to give your boat a new paint job or just touched up a few scratches, properly sanding fiberglass is an important step to ensure a smooth, even finish. Here’s a quick guide on how to sand fiberglass for paint:

Start with a coarse grit paper (40-60) to remove any existing paint or surface imperfections.
Progress to a medium grit paper (80-100) to smooth out the surface.
Finally, use a fine grit paper (200+) to achieve a glass-like finish.
For best results, wet sanding is recommended – simply soak the sandpaper in water for 10-15 minutes before use. This will help to prevent deep scratches and gouges.

How to prep fiberglass for paint

One way to do that is to make sure the fiberglass is properly prepared for painting. Here are some tips for prepping fiberglass for paint:

First, wash the area with boat soap and a soft brush. This will remove any dirt or grime that could prevent the paint from adhering properly.

Next, sand the area with fine-grit sandpaper. This will create a smooth surface for the paint to adhere to.

Finally, wipe down the area with a tack cloth to remove any dust from sanding.

If you have additional questions feel free to reach out to the Botton Paint Store technical team 888-505-2313.

West System to Hawk Epoxy Cross Reference Guide

Below shows the comparison of the West System products to the Hawk Epoxy products. Hawk Epoxy is comparable to the West System with how it works and its uses. West System epoxy is known for A/B/C/D selection system size (Size A resin with Size A hardener) the Hawk Epoxy uses 1/2/3/4 (Size 1 resin with Size 1 catalyst). The pumps are sold separate with West System and Hawk Epoxy, this works where 1 pump of resin is mixed with 1 pump of catalyst, or more depending on instructions. This is just to make it easier and less chance for error for the customer and it doesn’t mean a 1 to 1 ratio because the pumps are calibrated differently and each pump size can distribute different amounts.

Please Note: This chart simply shows the likely equivalent product by brand. It is not recommended to mix the products brands.

CLICK HERE: West System to Hawk Epoxy Cross Reference Guide.

West System and Hawk Epoxy are trade marks of Gougeon Brothers, and New Nautical Coatings, respectively.

How do I choose Hawk Epoxy Catalyst and Fillers?

R1 Epoxy Resin – a smooth, low-viscosity liquid epoxy resin. With a variety of Hawk Epoxy Catalysts, it can be cured under a wide range of temperatures and environmental conditions to form a high strength plastic with superior moisture barrier characteristics. Hawk Epoxy repair kit is available in four system sizes color coded on each label. Note: Mix ratios vary by catalyst. For optimal product utilization, be sure to choose the same Size for both the resin and catalyst. I.e Size 1 Resin with Size 1 Catalyst.

C1 ULTRA SLOW CURE CATALYST: Designed for use with HAWK EPOXY R1 Resin for construction and repairs with superior adhesion, strength, bonding, filling, and moisture barrier qualities at higher temperatures and for an ultra slow cure. Do not use under Sea Hawk marine wood varnish.

C2 SLOW CURE CATALYST: Designed for use with HAWK EPOXY R1 Resin for construction and repairs with superior adhesion, strength, bonding, filling, and moisture barrier qualities at higher temperatures and for a slow cure. Do not use under Sea Hawk marine wood varnish.

C3 FAST CURE CATALYST: Designed for use with HAWK EPOXY R1 Resin for construction and repairs with superior adhesion, strength, bonding, filling, and moisture barrier qualities at cooler temperatures and for a fast cure. Do not use under Sea Hawk marine wood varnish.

C5 CLEAR FINISH CATALYST: Designed for use with HAWK EPOXY R1 Resin for very clear fiberglass cloth and coating applications with exceptional moisture barrier characteristics. Perfect for natural wood and carbon fiber clear coats with no blush. Longer working times in very warm temperatures. May be used under Sea Hawk marine wood varnish.

TIP* For easy accurate measuring be sure to use the Hawk Epoxy Pumps that are calibrated to dispense the correct amount of resin and catalyst. This is much easier and leave little room for mistakes.

Next choose the best Hawk Epoxy Filler depending on the application:

F1 High Load Adhesive Fiber Filler – Thickens to a light grey color creating an easy to use adhesive designed for bonding hardware and other applications with dissimilar materials. This mixture will maximize bond strength for anticipated high loads.

F2 Structural Adhesive Filler – Thickens to an off white color, creating a general purpose thickening additive for bonding, gap filling and filleting. Mix to a workable consistency allowing sag-free and easy flow properties for vertical and overhead applications.

F-3 Light Density Adhesive Micro Fiber Filler – Thickens to an off white color. Great for bonding many substrates, especially wood. The mixture also creates a multipurpose adhesive for many other substrates in addition to providing excellent substrate wetting and penetrating characteristics. Increases impact and abrasion resistance.

F4 Bridging Adhesive Filler – Thickens to a brown color, creating an easy to use adhesive with excellent gap filling and filleting qualities. This mixture blends with many different types of wood to allow for a natural looking fillet or gap fill.

F5 Light Density Fairing Filler – Thickens to a reddish brown color, achieving an easy to sand and carve fairing compound while still remaining strong and light weight.

F6 MicroSphere Fairing Filler – Thickens to a white color, creating a lightweight fairing compound for small to large areas. This product holds a feathered edge very well and is suitable for nearly every substrate. This closed celled structure can also be used for increased acoustic and thermal insulation.

For the easiest way to choose your system, view our Hawk Epoxy Size 1 Kit

Aluminum Hull Repairs and More

How to Fix a Leaking Seam or Rivet on Aluminum Boat

As aluminum boats age they show various signs of wear and tear. One of these signs may be a leaking seam or rivet. Over time, rivets can stretched and loosen, causing a gap in the hull integrity and this results in a leak. The solution to this problem is fairly simple and may be fixed at home using just a few tools and know-how. So, how should this problem be addressed?

Locate the Leaking Rivet or Seam

The first step is to find the exact seam or rivet that needs repair. To do this, put the boat in water and observe carefully. You could also put water inside the boat and see where it allows the water to escape from.

Assess the Damage

The second step is assessing the extent of damage to the rivet or seam. If the seam is too wide to be filled or caulked, it will need additional rivets in combination with a sealant product. If the damage is easily visible a sealant or caulk will be sufficient.

Choose a Sealant or Epoxy Product

There are hundreds of products out there that claim to fix leaks and seal cracks. How do you know which to choose? The Bottom Paint Store has done most of the hard work for you and can confidently recommend 2 products that really work.

If your hull is bare aluminum you can cover the entire surface with a high build epoxy primer to help seal and protect it such as Tuff Stuff. For application details see our link for application of a marine epoxy.

Hawk Epoxy is an excellent product to repair aluminum hulls. We recommend getting one of the Hawk Epoxy Kits that will contain everything you need for filling in the aluminum. Hawk Epoxy is a versatile product that can be used for many other application too. Everyone should own this kit! See video for mixing and selecting fillers.

WEST SYSTEM 105 Epoxy Resin is a low viscosity, solvent-free epoxy resin. It is designed to wet-out and bond with wood, fiberglass, reinforcing fabrics and a variety of metals. It is an excellent adhesive that can bridge gaps and fill voids when modified with WEST SYSTEM fillers. The cured mixture can be sanded and shaped. WEST SYSTEM Epoxy Resin and hardeners can be used for everything from basic, long-lasting repairs to the construction of high-performance composite.

Another option is G/Flex 650 Epoxy made by West System. This liquid epoxy is more flexible and versatile than regular epoxies and will adhere to almost any surface. The bond that it creates can absorb shock, vibration, expansions and contractions. It will fully cure in 24 hours. Also, West System has created a detailed and comprehensive set of instructions for a wide variety of applications. They can be found at this link and below:

Fix leaking seams and rivets

Patch holes in aluminum hulls

Repair pitted or pin holed surfaces

Now that your leaky rivets and seams have been repaired, you are ready to paint! Check out this How To Article for more information on how to paint your aluminum vessel. Aluma Hawk is a great option or any of our antifouling copper free paint for aluminum.

Which Resin Should I Choose?

When it comes to boat repair, epoxy and polyester resins are both popular choices. But which one is the best option? Epoxy resin is known for its strong bonding properties, making it ideal for repairing cracks and holes. It also has excellent waterproofing qualities, making it ideal for boats that spend a lot of time in the water. Polyester resin, on the other hand, is a bit more flexible than epoxy, making it better suited for repairs that require some give. It’s also less likely to yellow over time, making it a good choice for boats that will be spending a lot of time in the sun. Ultimately, the best choice of epoxy or polyester resin for boat repair depends on the type of project you are tackling.

General Purpose Repair Epoxy Resin Kit

Every household should own a Hawk Epoxy Kit like this. You can use it to repair anything around your home or own your boat. This kit comes with the resin, catalyst and your choice of filler. Just mix them together and you have an excellent bonding, filling, or adhesive paste.

FGCI General Purpose Resin is used for laminating with fiberglass, kevlar and carbon reinforments. It can be tinted with pigment up to 3% and best results are when used at 70-85 degrees F. Hardener varies depending on thickness of fiberglass, the more fiberglass the less hardener as you will generate more heat-never go below 1%. Complete cure needs sanding aid added to resin or PVA while still hot.

Polyester Resin:

Polyester resins are unsaturated resins that are combined with hardeners, such as MEKP.

Polyester resin is used more for fiberglass lay-up or if you’re going to finish a repair with gelcoat, as the polyester resin will bond to the gelcoat better than epoxy. It is also cheaper than epoxy and a great choice when casting deep molds.

Various Types of Polyester Resin:

Boatyard Polyester Resin is a non-specified resin that contains different types of polyester resins and wax. Boatyard Polyester Resin is not recommended for use below the waterline. The material may cure hard and tack-free due to the included wax. If so, the product will need to be sanded prior to adding another layer in order to promote good bonding.

Clear Casting Polyester Resin is used to cast small objects into a mold. This method can be used to create sculptures, crafts, or industrial prototypes.

Surfboard Polyester Resin is Clear & wax free. It is ideal for building & repairing surfboards because it cures to an almost clear color when applied in a film. Also it highlights underlying graphics.

Iso Marine Resin is based on isophthalic acid. This resin is a step above the general purpose polyester resin and that is reflected in the price. Iso Resin is stronger, more durable, and is the best choice when applying in corrosion environments or elevated temperatures.

Vinyl Ester Resin:

Vinyl ester resins are formulated with a base of polyester resin strengthened with epoxy molecules (a hybrid form of polyester and epoxy and aiding for gelcoat to bond with epoxy) and also use peroxides, such as MEKP, for hardening. These are cheaper than epoxy resins and more expensive than polyester. Ideal temp for use is 77 F, not applied over 1/8th thickness or it will generate too much heat.

Vinyl esters are more tolerant of stretching, less likely to show stress cracking and more resistant to water penetration. Vinyl ester is the choice when improved resistance to moisture is the goal (like repairing a blistered hull).

Long term water exposure (hull or water tank) or if impact resistance is important vinyl ester is usually chosen.

Epoxy Resin:

Epoxy resins are cured with the addition of a hardener. Unlike the polyester and vinyl ester resins, cured with a small amount of catalyst, epoxy resins usually require a lot more, often 1:1 or 2:1. A epoxy resin is the most expensive of these.

Epoxy resin has the best bonding strength as it will bond dissimilar or already cured materials for strong, reliable repair work. This is the most expensive resin but offers the most in its ability to flex, prevent delamination and ease of repair work.

If doing a repair and not overlaying with gelcoat then the epoxy will perform best as it tends to act as a stronger “glue” for the patch to the surrounding surface.

Laminating Epoxy Resin is the correct choice for repairing boats. It is super durable and has high resistance to water. Also, it has very good adhesion to a variety of surfaces including metals, plastics, fiberglass, wood, and glass. The ratio is well suited for use with high-solids marine, maintenance coating and bonding agents. The cure time is three days in the sun or a week if it is not. Set time changes with activator and film thickness. If there is an excessive amount of activator applied , the laminating epoxy will be soft and rubbery. In contrast, if there is not enough activator, the epoxy will not cure hard. Laminating Epoxy is available in 3 different ratios that provide different working and cure times.

Epoxy Resin (Bar Top Epoxy Resin):

A Premium Commercial Grade Clear Epoxy Resin – Klear Kote Epoxy Resin is used extensively in coating surfaces and in table tops where a clear, hard and durable coating is required. Commonly seen on bar tops and restaurant tables. Easy to use 1:1 mixing ratio of resin and hardener. Items coated with it will become permanently preserved and protected for your enjoyment throughout a lifetime. The epoxy resin will not exhibit blushing or sweat out under high humidity conditions.

Epoxy Resin Kits

Epoxy resin kits are sold in two parts, A and B, which should be applied in two stages. The first stage is referred to as the seal coat. The seal coat is brushed on in a thin layer and is used to seal any pores on the surface and prevent air bubbles from forming in the following flood coats. This stage is followed by the flood coat, which will flow and self-level, clean brushes or squeegees can be used to help spread the epoxy. Flood coats are applied in 1/8″ layers at a time, as many as desired can be applied, however, one to three coats is average for most table or bar coatings. Resin kits are often applied on bar tops and tabletops in many bars and restaurants.

Superbond Standard Epoxy Glue

Superbond Standard Epoxy Glue is a two-part, 1:1 epoxy adhesive that has a Vaseline consistency. The product adheres to nearly everything and is a favorite among woodworkers. It’s offered in a fast curing agent, giving 8-15 minutes of working time; a medium, giving 20-30 minutes, and a standard, offering 30-45 minutes. SuperBond is offered in sizes from ½-pint tubs all the way to 5-gallon pails.

Rot Stop Epoxy

Rot stop epoxy is a 2-part epoxy that is 1:1 ratio and is very simple to mix. The coverage is similar to other epoxies, and like other epoxies, the product does vary in thickness based on temperature. The advantage of Rot Stop is it is NOT affected by moisture, making it excellent for deck or flooring and cracking repair, especially moisture damage.

See catalyst chart for mixing guidance:

MEKP Chart — **The weight of MEKP is 1/125 grams per CC. 30 Drops is approximately equal to one CC (Cubic Cementer)**
NOTE: Using drops for catalyst is only an estimate. In Critical applications MEKP should be measure by using CC’s or Fluid Ounces which are volume measurements. The percentages in the chart: 1% thru 2% are percentages of gelcoat by weight.The CC’s and OZ’s values in the chart have been converted from weight of MEKP to volumes of MEKP.

Resin guns

Gelcoat and resin spray guns are ideal for large surface spraying, such as new mold construction, composite refinishing and large boat surfaces. Look for a resin gun with a blue die cast body which will ensure a long life. Most HVLP cup guns use nylon flat seal just behind the threads that the air cap attaches to.

If you have used a spray gun with a nylon flat seal just behind the threads that the air cap attaches to and cleaned it with acetone, the seals disintegrate so it is best to use one with a plastic seal.

Can you use water-based bottom paint over a marine epoxy primer?

Epoxy paint is a latex acrylic substance that may have a small amount of epoxy in the mix and provide a tough, durable protective coating that’s effortless to maintain. Putting a water-based bottom paint (WBP) over a solvent based primer can be done with some modified application procedures. You do NOT want to make the window, or hot coat the water based paint over the solvent based primer such as Tuff Stuff high build marine epoxy primer. If you do, it will mud crack. So instead of putting on the WBP over the Solvent Primer in the same day, you need to wait for the primer to totally cure. Then you have to sand it with 80 grit sandpaper before apply WBP. This is a lot of extra work and very difficult to sand = extremely hard surface. So the best thing to do when using a high build solvent based epoxy is to coat it with a solvent based paint. That way you skip the extra time and labor with sanding.

Application of Marine Epoxy Primer to a Boat

Marine Epoxy systems on the bottom of bare fiberglass is the best way to protect your boat against blisters. It also provides added adhesion of the bottom paint to the hull. Here are the steps that you need to take for proper application of a marine epoxy primer (barrier coat system) to the bottom of a boat.

Preparation

Clean
When painting a bare fiberglass / gel coat hull for the first time, it is extremely important that all contaminants such as grease, oil, wax, salt, or other foreign material are completed removed prior to sanding or application of a Sea Hawk System. Scrub the surface with a detergent soap and stiff bristle brush.

A. Clean and de-wax fiberglass hull with S-80 Wax N’ Grease Killer solvent based dewax. Saturate cheesecloth rag and wipe thoroughly to remove any cleaner and contaminants. Be sure to remove any residue before it dries and change rags frequently to insure contaminants are completely removed.

B. Apply S-90 De-Wax Etch & Cleaner with a maroon 3M Scotch-Brite® pad scrubbing thoroughly. Do not allow cleaner to dry on the surface and remove by flushing with water.Rinse entire surface with water and check for any beading on the surface which will indicate that wax is still present. If necessary repeat step 2 again until the surface is contaminant-free. Choose your system below.

Sand and Clean
Sand to a uniformly frosty, dull looking surface with 80-100 grit (no finer) sandpaper, rewash with S-80 Wax N’ Grease Killer , S-90 De-Wax Etch & Cleaner .

Apply Marine Epoxy Primer
Seal the surface with 2-3 coats of Tuff Stuff Epoxy Primer. Apply the first coat of marine epoxy primer and allow the surface to dry to become tacky. Temperature and humidity affect the dry time, but you will know when to apply your next coat of marine epoxy primer once the paint film becomes “tacky”. You should be able to firmly press your thumb into the paint film and leave a thumbprint without any high build marine epoxy primer coming off the surface. You should use this method in between coats of marine epoxy primer and your first coat of bottom paint.

Tip: When applying marine epoxy primer over multiple days, it is always best to go overnight between coats of marine epoxy primer instead going overnight between the final coat of marine epoxy primer and the first coat of bottom paint. When over coating Tuff Stuff Epoxy Primer it is important to meet the required over coating times in order to achieve the best adhesion because temperature and humidity control dry times. It is hard to give exact times of cure. An easier rule in epoxies is when the coating is dry to the touch, yet still has some tack, it is ready to be over coated. However, if the coating is completely cured (after 24 hours) it needs to be thoroughly sanded with 80 grit sand paper to remove shine. If the marine epoxy primer is not sanded after full cure, bottom paint will not adhere.

Apply Bottom Paint to Marine Epoxy Primer
Apply minimum of two coats of bottom paint. Allow 3 to 6 hours between coats and a minimum overnight dry. See the specific Technical Data Sheet for bottom paint being used. Some bottom paint may require more than 2 coats.