Repairing cracks and holes in a polyester boat

Do you want to repair your polyester boat? At Polyestershoppen, we know everything about optimal repair of polyester boats. We also sell all supplies. You can call our website THE place for everything you need to repair or maintain your polyester boat.

Holes and cracks in polyester are in many cases easy to repair. Damage in polyester layers can often be recognized by fibers that are still visible. In this manual for repairing a polyester boat we will help you step by step to fully restore the damage to its original strength. Do you still need advice or are you unsure about using our products? Do not hesitate and feel free to contact our specialists. They will help you quickly and accurately!

Supplies for repairing a polyester boat:

• Polyester repair kit (small repairs) or polyester laminating kit (large repairs)
• Polyester safety package or gloves, vapor mask and safety goggles 
• Mixing spatulas
• Mixing cups
• Fiber disc with adapter and grinding tool

Roadmap for optimal polyester boat repair

Do you have all the products? Then it's time to start the repair work. Following the steps below will get your boat back in the water in no time!

Step 1. Clean the surface well and inspect the damage

Clean the surface around the damage well with acetone, for example. Look carefully at how far the hole or crack extends. 

Step 2. Grind/sand beveled edges into the hole or crack

It is important to grind bevels into the hole or crack before you begin the repair. This way, you will allow for proper adhesion and ensure that you can rebuild the hole or crack to the proper thickness.

Also sand around the hole for good adhesion for the overlapping fiberglass mats.

Step 3. Support the surface if possible

You can do this by stretching a piece of string into a piece of cardboard, for example. This will make sure it stays in place. You can also put a little polyester putty with hardener on the edges of the cardboard. That also sticks well.

Step 4. Laminating glass mat with polyester

Degrease the surface around the repair and then you can start rebuilding the fiberglass laminate. Mix the polyester resin with about 2% hardener and mix it well. Then use a brush to apply a little polyester resin around the repair and possibly on the piece of cardboard.

Tear the fiberglass mats into small pieces. Work from small to large. Place a mat on the hole and wet it thoroughly with polyester resin. Then you put a slightly larger piece of fiberglass mat over it and wet it again. Repeat this until you are at the original thickness and have overlap with the substrate around the crack or hole.

Step 5. Finishing and continuation

Let it harden for at least 24 hours and remove the string. After this it can be sanded with a coarse grit and finished further. This can be done with Polyester topcoat, for example, or by first filling it with filler and then varnishing it witht DD Lacquer.

Need help?

Not getting by on your own and need help repairing your polyester boat? No problem. Get in touch with us quickly. We can be reached on weekdays via phone, email, WhatsApp and livechat. We are happy to look at your project and always provide you with appropriate and personal advice. Before you know it, you can enjoy a wonderful sunny day on the water again!